USER INSTRUCTIONS. MX/DDC-100 Field Unit. Installation Operation Maintenance. Experience In Motion FCD LMENIM /08

Transcription

1 USER INSTRUCTIONS MX/DDC-100 Field Unit FCD LMENIM /08 Installation Operation Maintenance Experience In Motion

2 MX/DDC-100 Field Unit Installation and Operation Manual 2008 Copyright Limitorque. All rights reserved. Printed in the United States of America. Disclaimer This document is meant for use with MX Installation and Operation Manual for MX-05 through MX-40. Information in this document is also applicable to MX-85 through MX-150. No part of this book shall be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise without the written permission of Limitorque. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. This document is the proprietary information of Limitorque, furnished for customer use ONLY. No other uses are authorized without written permission from Limitorque. Limitorque reserves the right to make changes, without notice, to this document and the product it describes. Limitorque shall not be liable for technical or editorial errors or omissions made herein; nor for incidental and consequential damages resulting from the furnishing, performance or use of this document. The choice of system components is the responsibility of the buyer, and how they are used cannot be the liability of Limitorque. However, Limitorque s sales team and application engineers are always available to assist you in making your decision. This manual contains information that is correct to the best of Limitorque s knowledge. It is intended to be a guide and should not be considered as a sole source of technical instruction, replacing good technical judgment, since all possible situations cannot be anticipated. If there is any doubt as to exact installation, configuration, and/or use, call Limitorque at (434) The latest revisions to this document are available at 2

3 Contents 1 Introduction Purpose How to Use this Manual User Safety User Knowledge DDC-100 System Capabilities and Features General Specifications 7 2 System Components Introduction Hardware MX Actuator DDC 100 Field Unit Host Controller Master Station II Network Cable Software Modbus Protocol Modbus Function Codes Modbus Function Code 01 (Read Coil Status) Modbus Function Code 02 (Read Input Status) Modbus Function Code 03 (Read Holding Register) Modbus Function Code 04 (Read Input Register) Modbus Function Code 06 (Preset Single Register) Modbus Function Code 08 (Diagnostics) Modbus Function Code 15 (Force Multiple Coils) Modbus Function Code 16 (Preset Multiple Registers) 28 3 Installation and Configuration Site and Network Cable Preparation Site Preparation Network Cable Preparation Installation Verification Network Cabling Installation Verification Field Unit Installation Verification Field Unit Configuration Configuring Field Unit Parameters Configuration Confirmation Checking Connections View Settings Checking the Normal Display 44 4 Associated Documents 46 5 Troubleshooting 48 6 How to Order Parts 50 Appendix Wiring Diagram 52 Appendix MX/DDC Register Definitions 56 Appendix Typical DDC-100 Network Installation Assignments 62 3 flowserve.com

4 Figures Figure 1.1 Typical DDC-100 system with or without a Master Station II 6 Figure 2.1 MX-05 actuator 8 Figure 2.2 DDC-100 field unit 9 Figure 2.3 Typical direct-to-host arrangement 10 Figure 2.4 Typical Master Station II (rear view) 11 Figure 2.5 Redundant connection operation in redundant host loop topology 12 Figure 3.1 Network connections 30 Figure 3.2 Removing outer plastic jacket 31 Figure 3.3 Separating cable parts 32 Figure 3.4 Stripping conductors 32 Figure 3.5 Applying heat shrink tubing 33 Figure 3.6 Ring tongue connectors 33 Figure 3.7 Connecting network cable to MX terminal block 34 Figure 3.8 Redundant bi-directional loop topology 36 Figure 3.9 Daisy chain topology 37 Figure 3.10 Error Messages 44 Figure A.1 (1 of 2) Typical MX/DDC-100 wiring diagram 52 Figure A.1 (2 of 2) Typical MX/DDC-100 wiring diagram 53 Figure A.2 - MX Terminal block 54 Tables Table 2.1 Modbus function codes supported 14 Table 2.2 DDC-100 coil assignments, Modbus 05 command usage for digital outputs 14 Table 2.3 Status Bit Definitions 15 Table 2.3 Status Bit Definitions (continued) 16 Table 2.4 Register definitions 18 Table 2.4 Register definitions (continued) 19 Table 2.4 Register definitions (continued) 20 Table 2.5 DDC-100 coil assignments, Modbus 05 command usage for digital outputs 22 Table 2.6 Modbus 06 command and field unit holding register Table 2.7 Diagnostic Codes Supported by the DDC-100 Field Unit 27 Table 3.3 Network cable terminations 34 Table 3.4 MX/DDC digital input configurations (only one selection per row is permitted) 42 Table 3.5 MX/DDC digital inputs (cross-reference of various inputs) 42 Table 3.6 Digital input voltages 43 Table 3.7 MX/DDC digital outputs S1-2 and R

5 1 Introduction 1.1 Purpose This manual explains how to install and operate the Flowserve Limitorque MX /DDC-100 field unit and is to be used as an addendum to Bulletin FCD LMENIM2306, MX Electronic Actuator Installation and Operation Manual. Up to 250 actuators, each containing a DDC-100 field unit, may be connected by a single twisted-pair cable to form a DDC-100 network. This network permits the actuators to be operated by various control room devices such as a distributed control system (DCS), a programmable logic controller (PLC), or a personal computer (PC). The DDC-100 system communicates status and alarm data from each MX and valve. 1.2 How to Use this Manual Each section provides the MX user with information on installing and operating the MX field unit. Section 1 - Introduction Details user safety and knowledge requirements, system capabilities, and features. Section 2 - System Components Focuses on the description of the DDC-100 system hardware and software components. Section 3 - Installation and Configuration Provides details for installing and configuring a field unit. Section 4 - Associated Documents Provides a list of documents on related subjects for additional MX and DDC-100 system information. Section 5 - Troubleshooting Section 6 - How to Order Parts Appendix A - Wiring Diagram Details wiring connections. Appendix B - MX/DDC Register Definitions Appendix C - Typicl DDC-100 Network Installation Assignments 1.3 User Safety Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the equipment. The user must read and be familiar with these instructions before attempting installation, operation, or maintenance. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, warranty void, or operational difficulty. User must follow local and state safety regulations. Safety notices are presented in this manual in three forms: c c WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning notices could result in personal injury or death. a a CAUTION: Directs the user s attention to general precautions that, if not followed, could result in personal injury and/or equipment damage. NOTE: Highlights information critical to the user s understanding of the actuator s installation and operation. 5 flowserve.com

6 1.4 User Knowledge It is recommended that the user read this manual in its entirety before the DDC-100 equipped actuator is installed and operated. The user needs to have a fundamental knowledge of electronics and microprocessor concepts. An understanding of valve actuators and digital control systems is beneficial to the field unit user. 1.5 DDC-100 System Capabilities and Features Limitorque s distributed digital control (DDC) valve control network supports up to 250 actuators over a single twisted-pair cable using Modbus protocol. MX actuators and other devices can be accessed from a control room for integration with a plant asset management (PAM) system, distributed control system (DCS), programmable logic controller (PLC), or personal computer (PC) based network. The DDC-100 system consists of a host system, controller, network, and field units. A typical DDC-100 system is shown in Figure 1.1. Figure 1.1 Typical DDC-100 system with or without a Master Station II Host controller Optional Master Station Network RS MX field units (up to 250)

7 1.6 General Specifications Direct-to-Host Specifications: Direct connection to host controller Communicates using the Modbus protocol and the RS-485 electrical standards Configurable bitmap High-level surge protection on network Network Specifications: Redundant bi-directional loop or daisy chain topology Modbus protocol and the RS-485 electrical standards High speed up to 19.2 kbaud communications MX Field Unit Specifications: OPEN, STOP, and CLOSE commands ESD and MOVE TO position commands Actuator status and alarm messages Six digital inputs and two analog inputs for user (see Table 2.2, Register Definitions) Two surge-protected and mutually isolated communication channels MX local control panel configuration Torque output (for reference only) and position feedback User s analog input feedback Nine digital outputs maximum (three standard/six optional) Master Station II (Optional) Specifications: Supports all Limitorque DDC-100 field units: MX, L120, LY Controls up to 250 MOVs User-friendly touch panel operator interface: Permits configuration and control of DDC-100 network Configures communication to host or DCS (Distribution Control System) Password protected Optional Hot Standby Configuration: Automatically assumes control on Primary Master Failure or on command from the DCS or touch panel Provides realtime status of field units through continuous cyclical polling Modbus RTU and TCP/IP: Addressable RS-232/485/422 10/100 baset Built-in Web server for ease of actuator and network diagnostics 7 flowserve.com

8 2 System Components 2.1 Introduction This section gives an overview of the components used in the DDC-100 system. The field unit is installed in each MX actuator. The network cable connects the field unit to the network via the actuator terminal block. The network cable is connected to a host controller or Master Station II. 2.2 Hardware NOTE: Recommended storage procedures are detailed in Bulletin FCD LMENIM2314, MX Maintenance and Spare Parts Manual. Failure to comply with recommended procedures will void the warranty. For longer-term storage, contact Flowserve for procedures and recommendations. Figure 2.1 MX-05 actuator Piece Description 1 Handwheel 2 Declutch Lever 3 Oil Fills (dotted arrow depicts fill on declutch side) 4 Controls Compartment (field unit location) 5 LCD Display 6 Control Knobs 7 Ground Lug 8 Thrust/Torque Base 9 Conduit Entries 10 Terminal Compartment 11 Motor 12 Nameplate

9 2.2.1 MX Actuator The MX is a multi-turn valve actuator designed for operation of ON-OFF and modulating valve applications. This actuator controls the opening and closing of valves. See Figure 2.1. Features of the MX include: Non-intrusive setup Separately sealed terminal chamber Patented absolute encoder for valve position sensing (no battery required) 32-character graphical LCD display with 180 rotation Sophisticated electronic control, monitoring, and diagnostic capabilities with patented LimiGard technology DDC 100 Field Unit The DDC-100 field unit is installed in the MX controls compartment. This unit permits the actuator to be controlled by a host controller or Master Station II via the DDC-100 network. The field unit includes two high-level, surge-protected, and isolated network communication channels, configurable digital I/O, and configuration via LCD screen. The following commands and information may be transmitted over the DDC-100 network: OPEN, STOP, and CLOSE commands ESD and MOVE TO position commands Actuator status and alarm messages Six digital inputs and two analog inputs for user (see Table 2.2, Register Definitions) Two surge-protected and mutually isolated communication channels MX local control panel configuration Torque output (for reference only) and position feedback User s analog input feedback Nine digital outputs maximum (three standard/six optional) Figure 2.2 DDC-100 field unit 9 flowserve.com

10 2.2.3 Host Controller In the DDC-100 system, the network can be connected directly to a host controller without an interposing Master Station II. In this configuration, the host sends commands and messages to, and gathers responses from, the field units. The commands and messages are sent via RS-485 data signals. The gathered responses are stored in a data table in the host and are periodically updated by sequential polling of the field units. The host controls up to 250 field units. See Section , Network Cable Connection to Host System or Master Station II. When a host controller is used to directly communicate with the field units, i.e., direct-to-host communications, it communicates using the Modbus protocol and the RS-485 electrical standard. This host controller can be one of the following: Distributed control system (DCS) Programmable logic controller (PLC) Personal computer (PC) Plant Asset Management (PAM) system Figure 2.3 Typical direct-to-host arrangement DCS PC/PAM PLC RS-485

11 2.2.4 Master Station II A Master Station II may be used in the DDC-100 system. Master Station II s are normally located in the control room, and serve as the interface between the field units and the host controller. The following functions are provided: Continuous polling of actuator network Message routing to/from field units Data concentration Data logging In this configuration, the Master Station II receives commands from a host controller. The Master Station II communicates with the host controller using the Modbus Protocol and the RS-232 or RS-485 electrical standard. See Bulletin FCD LMENIM5001, DDC-100 Master Station II Installation and Operation Manual for details. The Master Station II sends commands and messages to, and gathers responses from, the field units. The commands and messages are sent via RS-485 data signals. The gathered responses are stored in a poll table in the Master Station II and are periodically updated by sequential polling of the field units. The Master Station II controls up to 250 field units. See Section , Network Cable Connection to Host System or Master Station II. Figure 2.4 Typical Master Station II (rear view) NO SERVICEABLE PARTS INSIDE 8 DO NOT USE WITH VAC EXTERNAL 24VDC INPUT ONLY VDC HOT STANDBY OPTIONAL PRINTER / DEBUG ETHERNET SINGLE PRINTER / DEBUG DO NOT USE WITH VAC EXTERNAL 24VDC INPUT ONLY VDC 4 MOVE JUMPERS ON INSIDE OF UNIT FOR PROPER OPERATION DCS DCS MOVE JUMPERS ON INSIDE OF UNIT FOR PROPER OPERATION 7 FUSES l o FUSES 2 AMP 250 V ON POWER OFF INPUT VAC ~1.5A CHANNEL A CHANNEL B DATA DATA * GND DATA DATA * GND FUSES 2 AMP 250 V ON POWER OFF INPUT VAC ~1.5A FUSES l o Ethernet ports 2. Printer/Debug port 3. DCS port 4. Auxiliary 24 VDC power connection 5. Main power switch and connector for VAC 6. Electrostatic ground 7. Hot Standby unit main power switch and connector for VAC 8. Hot Standby auxiliary 24 VDC power connection Hot Standby DCS Port 10. Hot Standby Printer/Debug Port flowserve.com

12 2.2.5 Network Cable The network consists of a shielded, twisted-pair cable that connects all field units and the host/master Station II. The cable is normally connected in a loop fashion so that any single break or short will not disable communication. Figure 2.5 Redundant connection operation in redundant host loop topology Signal initiated from host fails to reach field unit which is located after fault... Instead, signal routes to field unit using other side of the loop cable and completes connection. The network cable connects the field units to the host controller or Master Station II. Belden 3074F, 3105A, or 9841 shielded, twisted-pair cable should be used. The use of other cables may result in a reduction of internodal distances or increased error rate, and is the user s responsibility. Belden 3074F Specifications Total cable length between repeaters or nodes with repeaters, up to 19.2 kbps: 5000 ft (1.52 km) For loop mode, this is the total length between operating field units. If a field unit loses power, then the relays internal to the field unit connect the A1 Channel to the A2 Channel, which effectively doubles the length of the cable (assuming a single field unit fails). To ensure operation within specifications in the event of power failure to field units, this consideration must be added. Example: To ensure operation within specification when any two consecutive field units lose power, the maximum length of cable, up to 19.2 kbps, should not exceed 5000 ft (1.52 km) per every four field units. See Section , Network Cable Connection to Host Controller or Master Station II. Key Specifications Resistance/1000 ft = 18 AWG (7 x 26) 6.92 ohms each conductor (13.84 ohms for the pair) Capacitance/ft = 14 pf (conductor-to-conductor) Capacitance/ft = 14 pf (conductor-to-shield) 12

13 Belden 3105A Specifications Total cable length between repeaters or nodes with repeaters, up to 19.2 kbps: 4500 ft (1.37 km) For loop mode, this is the total length between operating field units. If a field unit loses power, then the relays internal to the field unit connect the A1 Channel to the A2 Channel, which effectively doubles the length of the cable (assuming a single field unit fails). To ensure operation within specifications in the event of power failure to field units, this consideration must be added. Example: To ensure operation within specification when any two consecutive field units lose power, the maximum length of cable, up to 19.2 kbps, should not exceed 4500 ft (1.37 km) per every four field units. See Section , Network Cable Connection to Host Controller or Master Station II. Key Specifications Resistance/1000 ft = 22 AWG (7 x 30) 14.7 ohms each conductor (29.4 ohms for the pair) Capacitance/ft = 11.0 pf (conductor-to-conductor) Capacitance/ft = 20.0 pf (conductor-to-shield) Belden 9841 Specifications Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 3500 ft (1 km) For loop mode, this is the total length between operating field units. If a field unit loses power, then the relays internal to the field unit connect the A1 Channel to the A2 Channel, which effectively doubles the length of the cable (assuming a single field unit fails). To ensure operation within specifications in the event of power failure to field units, this consideration must be added. Example: To ensure operation within specification when any two consecutive field units lose power, the maximum length of cable, up to 19.2 kbps, should not exceed 3500 ft (1 km) per every four field units. See Section , Network Cable Connection to Host Controller or Master Station II. Key Specifications Resistance/1000 ft = 24 AWG (7 x 32) 24 ohms each conductor (48 ohms for the pair) Capacitance/ft = 12.8 pf (conductor-to-conductor) Capacitance/ft = 23 pf (conductor-to-shield) 2.3 Software Modbus Protocol The Modbus protocol was developed by AEG Modicon for communicating to various networked devices. The relationship between these devices and a central controller is called a master-slave relationship in which the master (host device) initiates all communication. The slave devices (DDC-100 field units in the actuators) respond to the queries from the master. Modbus only permits one device to communicate at any given time (simultaneous communication is prohibited) to ensure process control integrity. 13 flowserve.com

14 2.3.2 Modbus Function Codes The controlling device (master) must conform to the Modbus protocol as defined in the Modbus-IDA Modbus Application Protocol Specification V1.1a ( and support Modbus function codes 01 through 06, 08, 15, and 16. These function codes are a subset of the complete protocol and are defined in Table 2.1. Table 2.1 Modbus function codes supported Extended Function Bit/Register Addressing Code Name Addressing Range 01 Read Coil Status Bit 0,000-9, Read Discrete Inputs Bit , Read Holding Register Register 40,000-49, Read Input Register Register 30,000-39, Force Single Coil Bit 0,000-9, Preset Single Register Register 40,000-49, Diagnostics N/A N/A 15 Force Multiple Coils Bit 0,000-9, Preset Multiple Registers Register 40,000-49,999 See Table 2.2 for a complete listing of MX/DDC holding registers Modbus Function Code 01 (Read Coil Status) This function code is used to read the coil status in the DDC-100 Field Unit. There are nine coils available to be read on DDC-100 Field Units as shown in Table 2.2. For the MX/DDC, Coil 1 indicates CLOSE contactor and is interlocked with Coil 2, Coil 2 indicates OPEN contactor and is interlocked with Coil 1. When the I/O Module is used in non-mov (motor-operated valve) mode, relays 1 through 6 or coils 3 through 8 are available for user configuration. Table 2.2 DDC-100 coil assignments, Modbus 05 command usage for digital outputs Coil Number Bit Number Function 1 00 Close/Stop 2 01 Open/Stop 3 02 S1 or R1 (Opt) Latched 4 03 S2 or R2 (Opt) Latched 5 04 R3 (Opt) Latched 6 05 R4 (Opt) Latched 7 06 R5 (Opt) Latched 8 07 R6 (Opt) Latched 9 08 R7 (Opt) Latched R8 (Opt) Latched The normal response to the (05) command is an echo of the command. Example Poll field unit number 3 for 8 coils starting at coil 1. Query: C2E Response: A 14

15 Message Breakdown Query Response 03 Slave (Field Unit) Address 03 Slave (Field Unit) Address 01 Function 01 Function 00 Starting Address Hi 01 Byte Count 00 Starting Address Lo 18 1 Data (Coils 8-1) 00 No. of Points Hi 503A Error Check (CRC) 08 No. of Points Lo 3C2E Error Check (CRC) Note 1: 18h equals or coils 4 and 5 are ON Modbus Function Code 02 (Read Input Status) This function code is used to read the discrete input status bits in the DDC-100 Field Unit. The use of this function code will provide the user with the input status bits that are used to develop holding registers 9 through 13. The status bit inputs are contained in locations for each DDC-100 Field Unit and are defined in Table 2.3. Table 2.3 Status Bit Definitions Bit Number Modbus Bit Address MX/DDC Opened Closed Stopped in mid-travel Opening Closing Valve jammed Not in remote Combined fault Over-temperature fault Actuator failing to de-energize Channel A fault Channel B fault Open torque switch fault Close torque switch fault Valve operated manually fault Phase error Open inhibit active Close inhibit active Not used Not used One or more phases is missing Reverse phase sequence is occurring ESD conflict Inhibit conflict Use in local/stop (input must be set for CSE and enabled) Not used Network emergency shutdown (ESD) is active Local emergency shutdown is active 15 flowserve.com

16 16 Table 2.3 Status Bit Definitions (continued) Bit Number Modbus Bit Address MX/DDC Field unit microprocessor has reset since the last poll MX in stop move Opening in local mode Closing in local mode Close contactor (interlocked) Open contactor (interlocked) S1 or R1 (opt) S2 or R2 (opt) R3 (opt) R4 (opt) R5 (opt) R6 (opt) R7 (opt) Network relay R8 (opt) Not used Mov series (0=1, A=9) Remote switch Thermal overload Open torque switch Open limit switch Close torque switch Close limit switch Not used Not used User Input User Input User Input Remote stop input Remote open input Remote close input Not used Not used Analog board 1 present Analog board 2 present Analog Input #1 lost Analog Input #2 lost Network Channels A/B timed out Relay board R5-R8 present DDC board present Relay board R1-R4 and RM present FF board present PB PA board present CLE assigned for input DNET board present

17 Table 2.3 Status Bit Definitions (continued) Bit Number Modbus Bit Address MX/DDC Lost Phase Input Phase Reverse Input Not used PB DP board present Example Poll field unit number 22 for 16 inputs starting at input 129 with the actuator opening. Query: B09 Response: CDED Message Breakdown Query Response 16 Slave (Field Unit) Address 16 Slave (Field Unit) Address 02 Function 02 Function 00 Starting Address Hi 02 Byte Count 80 Starting Address Lo 01 1 Data (Inputs ) 00 No. of Points Hi 08 2 Data (Inputs ) 10 No. of Points Lo CDED Error Check (CRC) 7B09 Error Check (CRC) Note 1: 01h equals (actuator open input bit is ON). Note 2: 08h equals (actuator Channel B Fail bit is ON) Modbus Function Code 03 (Read Holding Register) This function code is used to read the binary contents of holding registers in the DDC-100 Field Unit. This function code is typically used during the network polling cycle. A network poll should consist of field unit registers 9 (Status) and 10 (Fault) as a minimum. Holding register 8 should also be polled when the actuator is configured for the analog feedback option or position control. See Table 2.4 for a complete listing of the holding registers. 17 flowserve.com

18 Table 2.4 Register definitions Register # Description Meaning 1 Command Registers 1 and 2 are write-only registers used for Modbus Function Code 06 2 Argument Registers 1 and 2 are write-only registers used for Modbus Function Code 06 3 Analog Output 1 Analog Output 1 Value (Default 0-100) 1 4 Analog Output 2 Analog Output 2 Value (Default 0-100) 1 5 Analog Input Main Power (Volts) 6 Analog Input Analog Input 1 (Default 0-100) 1 User 4-20 ma / 0-20 ma Input 7 Analog Input Analog Input 2 (Default 0-100) 1 User 4-20 ma / 0-20 ma Input 8 Position Valve Position, Scaled Value (Default 0-100) 1 9 Status Register 16 Bits of field unit status: Bit 0 Opened Bit 1 Closed Bit 2 Stopped in Mid-Travel Bit 3 Opening Bit 4 Closing Bit 5 Valve jammed Bit 6 Not in Remote 2 Bit 7 Combined fault 3 Bit 8 Over temperature fault Bit 9 Future Implementation Bit 10 Network Channel A fault 4 (Terminals 5 and 4) Bit 11 Network Channel B fault 4 (Terminals 13 and 14) Bit 12 Open torque switch fault Bit 13 Close torque switch fault Bit 14 Valve-operated manually fault Bit 15 Phase error Note 1: Default value is scaled of span. Changes made to Analog Scale affect analog registers (3, 4, 6, 7, 8) and move-to commands. (0-100, 0-255, ) Note 2: MX/DDC actuators shipped after 2nd QTR, 1999, have the following definition of Register 9 Bit 6. When this bit has a value of 1 or true, the actuator is in LOCAL or STOP (unavailable for network control). The actuator selector switch in REMOTE (available for network control) is indicated by Register 12 Bit 0 having a value of 1 or true. IMPORTANT: Verify host program when installing an MX/DDC actuator shipped after 2nd QTR, 1999, on a network commissioned before 2nd QTR, 1999, for proper indication of selector switch values. Failure to verify proper selector switch indication at the host may cause unsafe conditions at the facility. MX/DDC actuators shipped prior to 2nd QTR, 1999, have the following definition for Register 9 Bit 6. When this bit has a value of 1 or true, the actuator selector switch is in LOCAL mode. This bit does not indicate STOP or REMOTE. The actuator selector switch in REMOTE (available for network control) is indicated by Register 12 Bit 0 having a value of 1 or true. Register 9 Bit 6 value 0 (zero) or false AND Register 12 Bit 0 value 0 (zero) or false indicates selector switch is in the STOP position. Note 3: Combined Fault bit is high when Bit 5 or 8 or 9 or 15 or (Bits 10 and 11) is high. Note 4: Channel A is physical connection A1. Channel B is physical connection A2. (See Appendix A.) 18

19 Table 2.4 Register definitions (continued) Register # Description Meaning 10 Fault Register 16 Bits of field status Bit 0 Open inhibit active Bit 1 Close inhibit active Bit 2 Not Used Bit 3 Not Used Bit 4 One or more phases are missing Bit 5 Reverse phase sequence is occurring Bit 6 ESD conflict Bit 7 Inhibit conflict Bit 8 CSE in local/stop (input must be set for CSE and enabled) Bit 9 Not Used Bit 10 Network emergency shutdown is active Bit 11 Local PB emergency shutdown is active Bit 12 Field unit microprocessor has reset since the last poll Bit 13 MX in stop mode Bit 14 Opening in local mode Bit 15 Closing in local mode 11 Digital Outputs Value of 16 Digital Outputs Bit 0 Close contactor (Interlocked) Bit 1 Open contactor (Interlocked) Bit 2 S1 or R1 (Opt) Bit 3 S2 or R2 (Opt) Bit 4 R3 (Opt) Bit 5 R4 (Opt) Bit 6 R5 (Opt) Bit 7 R6 (Opt) Bit 8 R7 (Opt) Bit 9 Network Relay Bit 10 R8 (Opt) Bit 11 Not Used BIT MOV Series (0 = 1, A = 9) 12 Digital Inputs 1 Value of 16 Digital Inputs Bit 0 Remote Switch Bit 1 Thermal Overload Bit 2 Open Torque Switch Bit 3 Open Limit Switch Bit 4 Close Torque Switch Bit 5 Close Limit Switch Bit 6 Not Used Bit 7 Not Used Bit 8 User Input 0 (Default=ESD), Terminal 30 Bit 9 User Input 1 (Default=Open Inhibit), Terminal 34 Bit 10 User Input 2 (Default=Close Inhibit), Terminal 35 Bit 11 Remote Stop Input, Terminal 26 Bit 12 Remote Open Input, Terminal 25 Bit 13 Remote Close Input, Terminal 27 Bits Not Used 19 flowserve.com

20 Table 2.4 Register definitions (continued) Register # Description Meaning 13 Digital Inputs 2 Value of 16 Digital Inputs Bit 0 Analog board 1 present Bit 1 Analog board 2 present Bit 2 Analog Input 1 lost Bit 3 Analog Input 2 lost Bit 4 Network Channels A/B timed out Bit 5 Relay board R5-R8 present Bit 6 DDC board present Bit 7 Relay board R1-R4 and RM present Bit 8 Foundation Fieldbus board present Bit 9 Profibus PA board present Bit 10 CSE chosen for input 2 Bit 11 DeviceNet board present Bit 12 Phase lost Bit 13 Phase reverse Bit 14 Not Used Bit 15 Profibus DP board present 14 Timers and Analog Channels Internal compartment temperature 1 15 User Faults Bits 0-15 Not Used 16 Current State Bits 0-15 Not Used 17 Field Unit Holding Register Special Applications Only 18 Field Unit Holding Register Special Applications Only 19 Field Unit Holding Register Special Applications Only 20 Field Unit Holding Register Special Applications Only 21 Field Unit Holding Register Special Applications Only 22 Field Unit Holding Register Special Applications Only 23 Field Unit Holding Register Special Applications Only Reserved Special Applications Only Not Named Special Applications Only 48 TP_START_POSITION Special Applications Only 49 TP_STOP_POSITION Special Applications Only 50 TP_SAMPLE Special Applications Only 51 TP_MID_T_HIGH Special Torque Applications Only 52 TP_MID_T_POS Special Applications Only 53 TP_MID_T_AV_VAL Special Torque Applications Only 54 TP_STOP_VAL Special Applications Only 55 TP_BEFORE_ MID_T_HIGH Special Torque Applications Only 56 TP_AFTER_ MID_T_HIGH Special Torque Applications Only Note 1: Range is +90 C to -55 C. High byte 00 indicates positive (+) and 01 indicates negative (-). Low byte indicates temperature value. Example: 0x0019 = +25 C 0x011E = -30 C Example Poll field unit number 125 for 3 registers starting at register 8 with the actuator stopped between the limits and in local mode. Query: 7D BFF6 Response: 7D D E07 20

21 Message Breakdown Query Response 7D Slave (Field Unit) Address 7D Slave (Field Unit) Address 03 Function 03 Function 00 Starting Address Hi 06 Byte Count 07 Starting Address Lo 00 Data Hi (Register 40008) 00 No. of Points Hi 3D 1 Data Lo (Register 40008) 03 No. of Points Lo 08 Data Hi (Register 40009) BFF6 Error Check (CRC) 44 2 Data Lo (Register 40009) 00 Data Hi (Register 40010) 00 Data Lo (Register 40010) 3E07 Note 1: 003Dh equals 61 Decimal (actuator Analog Input 1 in percent format). Error Check (CRC) Note 2: 0844h equals 2116 Decimal or Binary (actuator stopped between limits, local mode, and Channel B Fail bit is ON) Modbus Function Code 04 (Read Input Register) This function code is used to read the binary contents of input registers in the DDC-100 Field Unit. The typical use of this function code is to read the analog input registers. If the field unit is configured for scaled analog data, the register information will be returned as a percent from 0 to 100 (see NOTE below). The first analog input register (Analog 4) will start at register through (Analog 1) Input Register This function code may also be used to read the information available in registers 9 through 16. NOTE: Limitorque field units can be configured to report analog data in several formats. See the appropriate field unit manual for details. Example Poll field unit number 70 for 4 registers starting at register 5 (Analog Input Registers 1-4). (This example assumes that the field unit is configured for scaled analog data.) Query: BF7F Response: FFFFFFFF002B001EDBA8 21 flowserve.com

22 Message Breakdown Query Response 46 Slave (Field Unit) Address 46 Slave (Field Unit) Address 04 Function 04 Function 00 Starting Address Hi 08 Byte Count 04 Starting Address Lo FF Data Hi (Register 40005) 00 No. of Points Hi FF 1 Data Lo (Register 40005) 04 No. of Points Lo FF Data Hi (Register 40006) BF7F Error Check (CRC) FF 2 Data Lo (Register 40006) 00 Data Hi (Register 40007) 2B 3 Data Lo (Register 40007) 00 Data Hi (Register 40008) 1E 4 Data Lo (Register 40008) DBA8 Error Check (CRC) Note 1: FFFFh equals Decimal (actuator Analog Input 4 value). Note 2: FFFFh equals Decimal (actuator Analog Input 3 value). Note 3: 002Bh equals 43 Decimal (actuator Analog Input 2 value). Note 4: 001Eh equals 30 Decimal (actuator Analog Input 1 in percent format) Modbus Function Code 05 (Force Single Coil) This function code is used to force a single coil in the DDC-100 Field Unit. Forcing the individual coil either ON (1) or OFF (0) will energize or de-energize a coil (digital output) in the field unit. Coil 1 in the field unit closes the actuator and Coil 2 opens the actuator. If the actuator is opening or closing, changing the status of coil 1 or 2 from a value of 1 to 0 will stop the actuator (the coil will automatically be set to zero when the actuator reaches the full open or full close position). Available digital outputs for DDC-100 Field Units are listed in Table 2.5. Force-coil commands should be issued only once for the desired field unit control. Repeated issuance of an acknowledged command will degrade network performance. NOTE: See Bulletin LMAIM1329, Accutronix Installation and Operation for MX-DDC Field Unit to configure AS and AR Relays for DDC control. Table 2.5 DDC-100 coil assignments, Modbus 05 command usage for digital outputs Coil Number Bit Number Function 1 00 Close/Stop 2 01 Open/Stop 3 02 S1 or R1 (Opt) Latched 4 03 S2 or R2 (Opt) Latched 5 04 R3 (Opt) Latched 6 05 R4 (Opt) Latched 7 06 R5 (Opt) Latched 8 07 R6 (Opt) Latched 9 08 R7 (Opt) Latched R8 (Opt) Latched The normal response to the (05) command is an echo of the command. 22

23 Example of force coil command Force coil 1 of field unit 49 ON. This will CLOSE the valve controlled by field unit 49. Query: FF0089CA Response: FF0089CA Message Breakdown Query Response 31 Slave (Field Unit) Address 31 Slave (Field Unit) Address 05 Function 05 Function 00 Coil Address Hi 00 Coil Address Hi 00 1 Coil Address Lo 00 Coil Address Lo FF Force Data Hi FF Force Data Hi 00 2 Force Data Lo 00 Force Data Lo 89CA Error Check (CRC) 89CA Error Check (CRC) Note 1: 0000h equals Coil Address (field unit coil 1). 0001h equals Coil Address (field unit coil 2). Note 2: FF00h requests the coil to be ON. (0000h requests the coil to be OFF) Modbus Function Code 06 (Preset Single Register) This function code is used to preset a single register in the field unit. The function code is typically used to command the DDC-100 Field Unit by writing values to the and registers. A predetermined value may be used to open/stop/close the actuator, move the actuator to a preset position, activate/deactivate network ESD, reset the field unit, etc. The Modbus function code 06 is also used to command a throttling actuator to move-to a position of 0-100% of open. The field unit will compare the new position value with the current position and open or close the valve to meet the new position requirement. This is a two-step command: the first step is to write the desired position value to the field unit register 40002, then write the value of 6656 to field unit register This sequence of commands loads the desired position, then instructs the field unit to execute the command. For field units containing Modbus Firmware 2.00 or greater and MX-DDC field units containing Firmware 02/01.00 or greater, the move-to command may be executed with a one-step command. Modbus function code 06 command values for controlling the DDC-100 Field Unit are given in Table 2.6. Each command should be issued only one time for the desired field unit control. Repeated issuance of an acknowledged command will degrade network performance. The normal response to the (06) command is an echo of the command. NOTE: 1) Only use values listed in Table 2.6 For field unit register ) Field Unit Register should only be used for move-to position input. 3) The Host MUST issue move-to commands in the proper sequence. Failure to issue this two-step command in the correct sequence will result in the field unit waiting for the proper command sequence execution before performing the move-to function. 4) The move-to command should only be used with field units that include the position control option. 23 5) Do not write to Field Unit Registers flowserve.com

24 Table 2.6 Modbus 06 command and field unit holding register Host Commands to Field Unit Register 1 Value (Decimal) Function Null Command 0 No action Open 256 Open actuator Stop 512 Stop actuator Close 768 Close actuator Reset Field Unit 1024 Reset processor Start Network ESD 1280 ESD initiate Stop Network ESD 1536 ESD terminate Engage Relay # S1 or R1 (opt) Engage Relay # S2 or R2 (opt) Engage Relay # R3 (opt) Engage Relay # R4 (opt) Engage Relay # R5 (opt) Engage Relay # R6 (opt) Engage Relay # R7 (opt) Disengage Relay # S1 or R1 (opt) Disengage Relay # S2 or R2 (opt) Disengage Relay # R3 (opt) Disengage Relay # R4 (opt) Disengage Relay # R5 (opt) Disengage Relay # R6 (opt) Disengage Relay # R7 (opt) Move-To (Enable) Initiates move-to Engage Relay # R8 (opt) Disengage Relay # R8 (opt) Note 1: This is a two-step command. A valid value must be written to Register 2 before issuing this command. (See Note 1 of Table 2.2.) Other registers may also be preset to control or change other functions but care must always be taken to properly change these values. An improper value written to a register can cause undesirable actions from the DDC-100 Field Unit. NOTE: Null Command The field unit takes no action when this command is received. This command is typically used by a Host to reset the Host output register when required. Example of Field Unit Command Write the command to open an actuator (actuator open) to field unit number 179. This corresponds to writing the value 256 into field unit register Query: B Response: B Message Breakdown Query Response B3 Slave (Field Unit) Address B3 Slave (Field Unit) Address 06 Function 06 Function 00 Register Address Hi 00 Register Address Hi 00 1 Register Address Lo 00 Register Address Lo 01 Force Data Hi 01 Preset Data Hi 00 2 Force Data Lo 00 Preset Data Lo 9388 Error Check (CRC) 9388 Error Check (CRC) Note 1: 0000h equals Register Address (field unit register 1, command register). Note 2: 0100h requests the register to be preset with 256 Decimal (engage open contactor).

25 Example of Move-To Command Move an actuator at address 179 to 42% of open by first writing the value of 42 to the field unit register. After receiving a response from the field unit, write the value of 6656 to the field unit register. The actuator will then move to a position of 42% of open. First Command Query: B A4207 Response: B A4207 First Command Message Breakdown Query Response B3 Slave (Field Unit) Address B3 Slave (Field Unit) Address 06 Function 06 Function 00 Register Address Hi 00 Register Address Hi 01 1 Register Address Lo 01 Register Address Lo 00 Force Data Hi 00 Preset Data Hi 2A 2 Force Data Lo 2A Preset Data Lo 4207 Error Check (CRC) 4207 Error Check (CRC) Note 1: 001h equals Register Address (field unit register 2, argument register). Note 2: 002Ah equals 42. Second Command Query: B A Response: B A Second Command Message Breakdown Query Response B3 Slave (Field Unit) Address B3 Slave (Field Unit) Address 06 Function 06 Function 00 Register Address Hi 00 Register Address Hi 00 1 Register Address Lo 00 Register Address Lo 1A Force Data Hi 1A Preset Data Hi 00 2 Force Data Lo 00 Preset Data Lo 9978 Error Check (CRC) 9978 Error Check (CRC) Note 1: 0000h equals Register Address (field unit register 1, command register). Note 2: 1A00h equals Example of single register write move-to command This command allows a Host to issue the move-to command with a single write utilizing the Modbus function code 06. Register 1 will be used to complete this command. Rules for utilizing this command: Field unit scaling must be configured for To use the hexadecimal method of determining a single write move-to command, 0x4B is always placed into the Hi Byte of Register 1. The desired position value is always placed into the Lo Byte of Register flowserve.com

26 To move the actuator to a position of 50%, place the value 0x4B in the high byte and the value of 0x32 (50 decimal) into the low byte. Example: Hex format: 0x4B32 To use the decimal method of determining a single write move-to command, add the desired position value to Example: Desired position: 50% = Example of single write move-to command Move an actuator at address 1 to 50% of open by writing the value of (0x4B32) to the field unit register. The actuator will then move to a position of 50% open. Example Query: B323EEF Response: B323EEF Message Breakdown Query Response 01 Slave Address 01 Slave Address 06 Function 06 Function 00 Starting Address Hi 00 Starting Address Hi 00 Starting Address Lo 00 Starting Address Lo 4B Preset Data Hi 4B Preset Data Hi 32 Preset Data Lo 32 Preset Data Lo 3EEF Error Check (LRC or CRC) 3EEF Error Check (LRC or CRC) Modbus Function Code 08 (Diagnostics) This function code provides a series of tests for checking the communication system between the Host and field units (slaves), or for checking various error conditions within the field unit. This function code uses a two-byte subfunction code field in the query to define the type of test to be performed. The field unit echoes both the function code and subfunction code in a normal response. It does not affect the field unit in any way. If this exchange is successful, then the communication is successful. A listing of the supported diagnostic two-byte subfunction codes is given in Table 2.7. Example Request a loopback (return query data) from the field unit at network address 3. Query: E1E9 Response: E1E9 26

27 Message Breakdown Query Response 03 Slave (Field Unit) Address 03 Slave (Field Unit) Address 08 Function 08 Function 00 Subfunction Hi 00 Subfunction Hi 00 Subfunction Lo 00 Subfunction Lo 00 Data Hi 00 Data Hi 00 Data Lo 00 Data Lo E1E9 Error Check (CRC) E1E9 Error Check (CRC) Table 2.7 Diagnostic Codes Supported by the DDC-100 Field Unit Code Name 00 Return Query Data 01 Restart Communication Option 02 Return Diagnostic Register 1 03 Change ASCII Input Delimiter 04 Force Listen-Only Mode 10 (0A Hex) Clear Counters and Diagnostics Register 11 (0B Hex) Return Bus Message Count 12 (0C Hex) Return Bus Communication Error Count 13 (0D Hex) Return Bus Exception Error Count 14 (0E Hex) Return Slave Message Count Note 1: Contains DDC-100 Field Unit diagnostic information. For engineering use only Modbus Function Code 15 (Force Multiple Coils) This function code allows the user to force multiple coils with a single command and uses the same coil assignments as the function code 05. It should be noted that the coils are operated from the lowest coil number to the highest. Forcing coil 1 or 2 OFF (0) is considered a stop command, sending a 15 command to force two coils starting with coil 1, with coil 1 ON and coil 2 OFF, would result in the unit stopping, since coil 2 is forced OFF after coil 1 is forced ON. To prevent inadvertent Stop commands from being issued, it is recommended to force one coil at a time. Available digital outputs for DDC-100 Field Units are listed in Table 2.5. Force multiple coil commands should be issued only once for the desired field unit control. Repeated issuance of an acknowledged command will degrade network performance. Note: This function code is implemented in UEC-3-DDC Modbus Firmware 2.00 and greater and MX-DDC Firmware 02/01.00 and greater Example of force coil command Force coil 1 of field unit 1 ON. This will CLOSE the valve controlled by field unit 1. Query: 010F EF57 Response: 010F B 27 flowserve.com

28 Message Breakdown Query Response 01 Slave Address 01 Slave Address 0F Function 0F Function 00 Coil Address Hi 00 Coil Address Hi 00 Coil Address Lo 00 Coil Address Lo 00 Quantity of Coils Hi 00 Quantity of Coils Hi 01 Quantity of Coils Lo 01 Quantity of Coils Lo 01 Byte Count 940B Error Check (LRC or CRC) 01 Force Data Lo EF57 Error Check (LRC or CRC) Note: h equals Coil Address (field unit coil 1) h equals Coil Address (field unit coil 2) Modbus Function Code 16 (Preset Multiple Registers) This function code is used to preset single or multiple registers in the field unit and uses the same predetermined register values as the function code 06. This function code is typically used to command the DDC-100 Field Unit by writing values to the and/or registers. Modbus function code 16 command values for controlling the DDC-100 Field Unit are given in Table 2.6. Each command should be issued only one time for the desired field unit control. Repeated issuance of an acknowledged command will degrade network performance. The normal response returns the slave address, function code, starting address, and quantity of registers preset. Note: This function code is implemented in DDC Modbus Firmware 2.00 and greater and MX-DDC Firmware 02/01.00 and greater. Example of Field Unit Command Write the command to open an actuator (actuator open) to field unit number 1. This corresponds to writing the value 256 into field unit register Query: A7C0 Response: C9 28 Message Breakdown Query Response 01 Slave Address 01 Slave Address 10 Function 10 Function 00 Starting Address Hi 00 Starting Address Hi 00 Starting Address Lo 00 Starting Address Lo 00 Number of Registers Hi 00 Number of Registers Hi 01 Number of Registers Lo 01 Number of Registers Lo 02 Byte Count 01C9 Error Check (LRC or CRC) 01 Preset Data Hi 00 Preset Data Lo A7C0 Error Check (LRC or CRC)

29 Example of Move-To Command Move an actuator at address 1 to 50% of open by presetting registers with the value 6656, and register with the value 50 in a single write command. The actuator will receive this message and move to a position of 50% open. Query: A Response: C8 Message Breakdown Query Response 01 Slave Address 01 Slave Address 10 Function 10 Function 00 Starting Address Hi 00 Starting Address Hi 00 Starting Address Lo 00 Starting Address Lo 00 No. of Registers Hi 00 No. of Registers Hi 02 No. of Registers Lo 02 No. of Registers Lo 04 Byte Count 41C8 Error Check (LRC or CRC) 1A Preset Data Hi 00 Preset Data Lo 00 Preset Data Hi 32 Preset Data Lo 7562 Error Check (LRC or CRC) Note: The single register write Move-to command may also be used with the function code 16. This function code may also utilize the Single Register write move-to command. 29 flowserve.com

30 3 Installation and Configuration 3.1 Site and Network Cable Preparation Site Preparation Prepare the site and associated equipment for operation of the DDC-100 controlled MX actuators as follows: 1. Prepare a detailed site plan consisting of the following: Actuator locations, tag numbers, DDC addresses Junction boxes, terminal strip locations, and tag numbers 2. Provide free access to the MX control panel and terminal block for setup, configuration, and troubleshooting. 3. Prepare cable and label all wires. See Section 3.1.2, Network Cable Preparation. 4. nstall power and control wires in separate conduits. Shielding is not sufficient to prevent induction of stray voltages onto signal leads from the power lines. 5. Install and verify earth grounds. NOTE: Limitorque defines an effective local earth ground as a low impedance (less than 5 ohms) path to: A ground electrode placed in close vicinity of the actuator that is free of ground loop currents. OR A safety ground that is free of ground loop currents running from the actuator back to the system ground electrode. If the signal wiring is run on aerial cable where it may be exposed to high-energy electrostatic discharge (such as lightning), a low impedance path to ground that is capable of high current must be provided a short distance from the actuator as described above. OR A power distribution grid identifying the impact of power isolation to a particular actuator or group of actuators should be provided Network Cable Preparation Network Cable Connection to the Field Unit The DDC-100 field unit is connected to the network via the MX terminal block. The network cable is connected to the terminal block as shown in Figure 3.1. Figure 3.1 Network connections 30 NOTE: 1. Shielded, twisted-pair cables should be used. 2. Shields are connected to earth ground at one end only to avoid ground loops.

31 3. Clean earth-ground connection (less than 5 ohms) enhances noise rejection and provides a clear/safe path for surge currents. Prepare the network cable for connection to the MX terminal block as follows. a a CAUTION: Strip stranded conductors carefully; do not damage the strands. This will weaken the conductor. Do not nick conductors or conductor insulation when stripping away the insulation. Nicking stresses the conductor and can cause the conductor to break. This type of damage may not be apparent and failure can occur later without warning. NOTE: Multi-pair cables should provide shielding for each conductor pair. NOTE: Excess cable should be cut, not coiled or looped, to prevent noise induction into the network and to reduce signal loss through unnecessarily long cable runs. Cable Preparation 1. Remove two to three inches (5 to 8 cm) of the outer plastic jacket as shown in Figure 3.2. Figure 3.2 Removing outer plastic jacket 31 flowserve.com

32 2. Separate the cable parts. Unbraid the shield and peel back the foil shield to the same point where the outer jacket was removed as shown in Figure 3.3. Figure 3.3 Separating cable parts 3. Cut away the braided shield and the foil shield. Strip the insulation from the conductors approximately 0.4 inch (1 cm) as shown in Figure 3.4. Figure 3.4 Stripping conductors 32

33 4. Apply heat shrink tubing to insulate the drain wire and to provide stress relief to the cable as shown in Figure 3.5. Figure 3.5 Applying heat shrink tubing a a CAUTION: Do not melt the insulation. NOTE: Ungrounded drain wires should be cut even with the cable sheath. The brand foil and drain wire should have heat shrink tubing applied. 5. Install ring tongue connectors as shown in Figure 3.6. Flowserve recommends the use of Thomas & Betts #RZ22-6 for optimum results. Figure 3.6 Ring tongue connectors 33 flowserve.com

34 6. Connect the network cables to the MX terminal block as shown in Figure 3.6. Table 3.3 defines each network cable termination. Refer to Figure 3.8 and 3.9 for topology-specific wiring connections. Table 3.3 Network cable terminations Terminal Block Number Function 4 NETWORK 5 NETWORK 14 NETWORK 13 NETWORK 3 NETWORK SURGE (EGND) NOTE: Ground each segment of the cabling at only one point to prevent ground loops, which can affect system performance. Verify the actuator is properly grounded. 7. Install jumper cable from terminal block pin 3 to earth ground or ground lug. Figure 3.7 Connecting network cable to MX terminal block 34

35 Network Cable Connection to Host Controller or Master Station II Two network topologies are commonly used and supported for the MX: Redundant bi-directional loop (recommended) Daisy chain Redundant Bi-Directional Loop The redundant bi-directional loop topology requires two serial communication ports on the host device. Each field unit can be accessed by two host/master ports. The connections from the serial ports to the field units and connections between field units are made with shielded, twisted-pair cable in a loop configuration. A single line break or short can occur while maintaining communication to all field units. Figure 3.8 shows the redundant bi-directional loop network topology for a direct-to-host connection. The redundant bi-directional loop topology is wired as follows: see Figure Connect the host device port 1, through an RS-232 to RS-485 converter if required, to the first field unit port A1 at MX terminal block numbers 4 and Connect the port A2 at MX terminal block numbers 14 and 13 to the next field unit s port A1. 3. Each subsequent field unit is connected in the same manner receiving data through its port A1, then passing the data out through its port A2 to the next field unit. 4. The last field unit s port A2 is connected to the host device s port 2. The host device should be configured to ignore messages that it sends out when it returns to its other port. The direction of data flow can be reversed because of the bi-directional capability of the serial ports. a. Communications can be initiated by connecting host port 2 to first field unit port A2. b. Port A1 of the first field unit is then connected to port A2 of the next field unit. c. Port A1 of the last field unit is then connected to host port 1. In either direction, the signal is regenerated in each field unit to permit long-distance communication with reduced noise sensitivity and improved reliability. 35 flowserve.com

36 Figure 3.8 Redundant bi-directional loop topology Legend MOV - Motor-operated valve 5 - Data A1 4 - Data A1* 13 - Data A Data A2* - Shield N/C - No connection Data terminal is positive with respect to data* terminal MOV-1 See Note 5 MOV-2 See Note 5 MOV-3 See Note 5 Data 1 Data* 2 Ground 3 N/C 3 3 A1* 4 A1* 4 A1 5 A A2* 14 A2* 13 A2 N/C 13 A2 N/C 3 A1* 4 A A2* A2 N/C Host (Network controller) RS-485 PORT 1 Network port A RS-485 PORT 2 Network port B Data 1 Data* 2 Ground 3 Earth ground (See Note 4) N/C MOV-250 See Note 5 3 A1* 4 A A2* 13 A2 N/C MOV-249 See Note 5 MOV-248 See Note A1* 4 A1* 4 A1 5 A A2* 14 A2* N/C 13 A2 13 A2 Earth ground (See Note 4) Notes: 1. Belden 3074F, 3105A, or 9841 shielded cable is recommended. 2. Correct polarity for field unit and network controller connection is necessary for proper operation. 3. Connections shown are typical. The number of MOVs shown may not indicate true system size. 4. Earth ground: ground rod 5. Earth ground: ground rod or lug in actuator if actuator is grounded. Diagnostic note: Polarity and level of the network s data connection can be checked by measuring voltage between data and data* terminals. This voltage should be greater than +200 mv DC with network controller (host) network ports disconnected. Data terminal is positive with respect to data* terminal. Earth ground note: If low impedance earth ground is not available at each actuator, contact engineering for alternative earth ground surge protection strategies. Daisy Chain The daisy chain topology is identical to the redundant loop topology with the following exception: only one end of the network is connected to the host device. The daisy chain topology is wired as follows: 1. Connect the host port 1 to the first field unit port A1 at MX terminal block numbers 4 and Connect port A2 of this field unit at MX terminal block numbers 14 and 13 to port A1 of the next field unit. 3. Continue steps 1 and 2 until the last field unit is connected. 36 NOTE: If a stub cable is run from port A2 of the last field unit (MX terminal block numbers 14 and 13) to a planned field unit location, or the last field unit is disconnected, the open end of the cable must be terminated with a 120 ohm resistor to prevent unacceptable signal reflections. Termination impedance is supplied when the actuator field unit is the last unit. The daisy chain topology utilizes the field unit repeater circuitry, and therefore supports the same number of field units and distances as the redundant bi-directional loop topology. However, the daisy chain topology is less reliable than the redundant bi-directional loop topology because the host can only reach the field units from one direction. If a data cable break occurs, communication will be lost to all nodes on the far side of the break.

37 Figure 3.9 Daisy chain topology Legend MOV - Motor-operated valve 5 - Data A1 4 - Data A1* 13 - Data A Data A2* - Shield N/C - No connection Data terminal is positive with respect to data* terminal Host (Network controller) MOV-1 See Note 5 MOV-2 See Note 5 MOV-3 See Note 5 RS-485 PORT 1 Network port A Data 1 Data* 2 Ground 3 N/C A1* A1* A1* A1 5 A1 5 A A2* 14 A2* 14 A2* N/C N/C 13 A2 13 A2 13 A2 N/C Earth ground (See Note 4) MOV-250 See Note 5 MOV-249 See Note 5 MOV-248 See Note 5 3 A1* 4 A A2* A2 N/C 3 A1* 4 A A2* 13 A2 N/C 3 A1* 4 A A2* 13 A2 Notes: 1. Belden 3074F, 3105A, or 9841 shielded cable is recommended. 2. Correct polarity for field unit and network controller connection is necessary for proper operation. 3. Connections shown are typical. The number of MOVs shown may not indicate true system size. 4. Earth ground: ground rod 5. Earth ground: ground rod or lug in actuator if actuator is grounded. Diagnostic note: Polarity and level of the network s data connection can be checked by measuring voltage between data and data* terminals. This voltage should be greater than +200 mv DC with network controller (host) network ports disconnected. Data terminal is positive with respect to data* terminal. Earth ground note: If low impedance earth ground is not available at each actuator, contact engineering for alternative earth ground surge protection strategies. 37 flowserve.com

38 3.2 Installation Verification Network Cabling Installation Verification After installation is complete and prior to operation, inspect the network cable and its connection to each field unit for the following: NOTE: Units should be disconnected from power. Network should be disconnected from host. 1. There should be: No nicks in the insulation this can cause a short between conductors or to the grounded shield. No cut strands in a stranded conductor this can cause a poor connection and eventually an open circuit. 2. Verify that there is data wiring on each actuator per wiring diagram. 3. Cable armor should not be shorted to the cable shield/drain wire. Cable armor may not be at ground potential and could be subject to lightning surges. 4. The shield/drain wire should only be grounded at one end of each cable segment (the section between adjacent actuators or between the host system/master Station II and an actuator) to avoid ground loop problems. 5. The ground/earth connection should be at true ground potential and effective at all times. See No. 5 in Section 3.1.1, Site Preparation. For the redundant bi-directional loop, use a voltmeter in the control room. Determine the following by measuring resistance of individual wires in the network cables: Note: Power must be OFF on all field devices, and A1/A2 cables must be disconnected from the network host. 1. Data wire A1 to data wire A2 should be equal to the resistance value of network cable length/cable resistance per 1000 ft. 2. Data* wire A1 to data* wire A2 should be equal to the resistance value of network cable length/cable resistance per 1000 ft. 3. Confirm open circuit between data and data* cables. 4. Confirm open circuit between data, data*, and shield. 5. Confirm open circuit between shield and shield Field Unit Installation Verification Note: Connect to either 24 VDC power or mains and activate power. Verify the field unit is installed as follows: 1. Enter the SETUP mode as detailed in Bulletin LMENIM2306, MX Installation and Operation Manual. 2. In the SETUP mode, use the black control knob to select YES to the main menu selection VIEW DIAGNOSTICS? 3. Select YES to the display VIEW HARDWARE STATUS? Select YES to scroll through the menu selections. The LCD will read DDC (OK) NEXT? if installed. NOTE: If the DDC (OK) NEXT? does not appear, contact Flowserve for assistance. 5. To return to the normal display, use the red knob to select either LOCAL or REMOTE.

39 3.3 Field Unit Configuration The actuator has been configured with all customer-specified parameters and no further calibration should be necessary. Only the address needs to be configured. If full valve data was not provided when ordering, or if changes are needed for parameters other than the DDC option, refer to Bulletin LMENIM2306, MX Installation and Operation Manual. If any changes to the DDC configuration are required, see Section 3.3.1, Configuring Field Unit Parameters Configuring Field Unit Parameters The following instructions assume that all MX and DDC parameters are set, except the address. 1. Enter the SETUP mode as detailed in Bulletin LMENIM2306, MX Installation and Operation Manual. 2. When LCD reads CHANGE SETTINGS?, use the black knob to select YES. 3. Enter password. (100=Default) 4. The LCD will display the CHANGE SETTINGS mode menu items. Select NO until screen displays CHANGE DDC? Select YES. LCD will display DDC menu items. 5. Select YES to each menu item until DDC ADDRESS OK? appears. Select NO if address displayed is not correct. 6. Enter an address from 1 to 250 by toggling NO until the correct address is displayed. 7. Return red selector switch to REMOTE or LOCAL to save address. a a CAUTION: The network address must be entered in accordance with the user address assignment sheet. This assignment sheet should correspond to the contract specifications. The same address must not be used anywhere else in the same network. All DDC parameters have been factory-set in accordance with customer specifications or defaults. These parameters may be viewed or changed as described in Bulletin LMENIM2306, MX Installation and Operation Manual Viewing DDC Parameters Enter the VIEW SETTINGS mode and VIEW DDC? as detailed in Bulletin LMENIM2306, MX Installation and Operation Manual. The display will show the state or value of the following menu items: Status (ON or OFF) DDC Address Protocol (Baud Rate) Analog Scale ESD Action Proportional Band Deadband Offset Move To Comm Loss Delay Comm Loss Action NOTE: VIEW DDC? will not appear if the DDC-100 Network Board is not installed. If the VIEW DDC? does not appear, contact Limitorque. 39 flowserve.com

40 Changing DDC Parameters Enter the CHANGE SETTINGS mode and CHANGE DDC? as detailed in Bulletin LMENIM2306, MX Installation and Operation Manual. The following parameters may be changed: Status (ON or OFF) Protocol (Baud Rate) DDC Address Analog Scale ESD Action Proportional Band Deadband Offset Move To Comm Loss Delay Comm Loss Action Each parameter is discussed below: Status (ON or OFF) This parameter activates or deactivates the field unit. NOTE: When the field unit is installed at the factory, the default status is ON. If DDC status is OFF, the LCD screen will display XXX% OPEN, DDC OFF. Use the black control knob to select NO, which toggles the field unit OFF and ON. If DDC option is ON, the Modutronic option must be OFF. Use the Modutronic option to configure the proportional band and deadband for move-to control. Protocol (Baud Rate) The protocol and baud rate selected depend on the system design. All field units and the host system/master Station II must have the same protocol and baud rate. 1. Using the black control knob, actuate NO to change the protocol/baud rate. Possible selections are: 40 MODBUS RTU 19.2k BAUD MODBUS RTU 9600 BAUD MODBUS RTU 4800 BAUD MODBUS RTU 2400 BAUD MODBUS RTU 1200 BAUD MODBUS ASCII 19.2k BAUD MODBUS ASCII 9600 BAUD MODBUS ASCII 4800 BAUD MODBUS ASCII 2400 BAUD MODBUS ASCII 1200 BAUD NOTE: All field units must have same configuration either RTU or ASCII. 2. Select YES to choose the proper protocol/baud rate.

41 DDC Address The network address must be entered in accordance with the Instrument Data Sheet, and care must be taken to ensure that the same address is not used anywhere else in the same network. Select NO for small incremental changes or hold it continuously in that position for larger changes until the required value is displayed. The address may be set at any value between 001 and 250. c c WARNING: Each actuator must have a unique address. Analog Scale The digital values of external analog data received over the DDC network may be scaled as shown below to suit the users preference. Using the black control knob, select NO until the required scale is displayed. The scale options are as follows: of span of span of span The changing of the analog scale will affect all the digital values in registers 3, 4, 6, 7, 8 and move-to commands. Scaling conventions must be consistent between the field unit and host device. Standard Digital Inputs (Register 12, Bits 08 13) The field unit contains six digital inputs for monitoring the status of external contacts. The inputs may be powered one of two ways: From the MX (24 VDC) From the customer s source (24 VDC or 120 VAC) NOTE: These digital inputs are meaningful only when DDC option is used. The six standard digital inputs may be configured in a number of ways for monitor and/or control. (See Table 3.4 and Table 3.5.) In any selected configuration, the inputs may be monitored via the DDC-100 network by reading the field unit holding registers and The presence of voltage on a terminal will indicate a TRUE condition. The absence of voltage will indicate a FALSE condition. Depending on configuration, the host may read the digital input to monitor field-installed devices connected to the MX/DDC input OR may monitor the digital input to verify an actuator function in relation to a preselected condition (ESD, Hardwire Remote Control, Inhibits) Configuring for Position Control or Move-To Operation (Option) The MX/DDC contains a default proportional band value of 15% and a deadband value of 2%. The MX/DDC may be sent to an intermediate position by utilizing the Modbus function code 06. First issue the desired position, then issue the move-to enable (see Table 2.4). To alter the default proportional band and deadband values, the modulating position control (MPC) feature must be enabled. MX/DDC field units are shipped without MPC enabled, but this feature may be enabled in the field. Please contact the Flowserve Limitorque Service Department to order the MPC feature which allows adjustments of the proportional band and deadband values. NOTE: If DDC option is ON, the Modutronic option must be OFF. 41 To alter proportional band and deadband values: (Refer to Bulletin LMENIM2306, Section: Modutronic Option) flowserve.com

42 1. change modutronic? 2. Select yes. 3. status (on) ok? 4. Select yes. 5. prop band (15%) ok? 6. Select NO until desired position is viewed. Then select yes. 7. fail position (close) ok? 8. Select NO until desired position is viewed. Then select yes. (This setting will have no meaning with DDC.) 9. deadband (2%) ok? 10. Select NO until desired value is viewed. Then select yes. 11. polarity 20mA=open ok? 12. Select yes. 13. delay after stop 0 seconds ok? 14. Select yes mA signal range? 16. Select NO. 17. change modutronic? 18. Select yes. 19. status (on) ok? 20. Select NO. 21. status (off) ok? 22. Select yes. 23. Exit Setup. NOTE: Modutronic STATUS must be OFF, once the proportional band and deadband values are changed. Table 3.4 MX/DDC digital input configurations (only one selection per row is permitted) Digital Input Default Digital Input Digital Input Options ESD User Input 0 Open/Close Inhibit, Both Inhibits, User Defined Open Inhibit User Input 1 Open/Close Inhibit, Both Inhibits, User Defined Close Inhibit User Input 2 Open/Close Inhibit, Both Inhibits, User Defined, CSE Remote Three-Wire Inching User Input 3,4,5 Three-Wire Maintained, Four Wire Table 3.5 MX/DDC digital inputs (cross-reference of various inputs) 42 Terminal # Basic Function Digital Input True Value 1 False Value Register. Bit 30 ESD Input (default) User Input Open Inhibit (default) User Input Close Inhibit (default) User Input Stop PB Input User Input Open PB Input User Input Close PB Input User Input Note 1: True value indicates voltage present at terminal point.

43 Table 3.6 Digital input voltages Terminal # Minimum ON Maximum OFF Maximum Load Minimum Signal Duration VAC/DC 5.0 VAC/DC 10 ma / 110 VAC 350 ms 2 ma / 24 VDC VAC/DC 5.0 VAC/DC 10 ma / 110 VAC 350 ms 2 ma / 24 VDC VAC/DC 5.0 VAC/DC 10 ma / 110 VAC 350 ms 2 ma / 24 VDC VAC/DC 5.0 VAC/DC 10 ma / 110 VAC 350 ms 2 ma / 24 VDC VAC/DC 5.0 VAC/DC 10 ma / 110 VAC 350 ms 2 ma / 24 VDC VAC/DC 5.0 VAC/DC 10 ma / 110 VAC 350 ms 2 ma / 24 VDC Digital Outputs (Register 11, Bits 02 & 03 [S]; Register 11, 02-08, 10 [R])) Four latching digital outputs are provided to control external equipment; S1a, S1b, S2a, S2b as standard. Two contacts may be individually configured for normally open, normally closed, or blinker operation. The remaining two contacts are complementary. These are normally configured to trip when the valve reaches the OPEN and CLOSED positions. However, the configuration may be changed to DDC CONTROLLED, in which case these contacts may be opened and closed over the network. Each of the digital outputs may be configured for one of the following functions: Closed, Closing, Mid-travel, Open, Opening, Stopped, Valve moving, Local selected, Local STOP/OFF, Manual operation, Valve jammed, Remote selected, Motor overtemp, Overtorque, Open torque switch, Close torque switch, ESD signal, Open inhibit, Close inhibit, Lost phase, No analog signal, Hardware failure, Network controlled, CSE controlled. See LMENIM2306, MX Installation and Operation Manual. Register 11 is used only for status (read-only). When the optional relay board is supplied and the relays are enabled, up to eight latching relays may be monitored or controlled. (See Table 3.7.) Each of the digital outputs may be configured for one of the following functions: Closed, Closing, Mid-travel, Open, Opening, Stopped, Valve moving, Local selected, Local STOP/OFF, Manual operation, Valve jammed, Remote selected, Motor overtemp, Overtorque, Open torque switch, Close torque switch, ESD signal, Open inhibit, Close inhibit, Lost phase, No analog signal, Hardware failure, Network controlled, CSE controlled. NOTE: Digital outputs must have corresponding digital feedback (digital input) to verify digital output position. Table 3.7 MX/DDC digital outputs S1-2 and R1-8 Digital Output Terminals Default Config. Register. Bit S1 44, 45 (N.O.) Closed , 49 (N.C.) S2 50, 51 (N.O.) Open , 47 (N.C.) R1 (opt.) 44,45 Closed R2 (opt.) 46, 47 Open R3 (opt.) 48,49 Closed R4 (opt.) 50, 51 Open R5 (opt.) 36, 37 Motor Overtemp R6 (opt.) 38, 39 Remote Selected R7 (opt.) 40, 41 Overtorque R8 (opt.) 42, 43 Analog Input Lost flowserve.com

44 3.4 Configuration Confirmation Field unit operation cannot be verified until the complete DDC-100 system is operational. However, routine checks can be performed to verify many functions Checking Connections Verify that all connections, including data wires, shield ground, digital inputs (optional), digital outputs (optional), and analog inputs (optional) are in accordance with MX wiring diagrams and field unit diagrams in Section 3.1.2, Network Cable Preparation View Settings Refer to LMENIM2306, MX Installation and Operation Manual to access the VIEW SETTINGS menu. Verify the settings as follows: 1. Confirm the DDC status is ON. 2. Confirm the address for each field unit is correct and unique. 3. Confirm the baud rate and the protocol are correct. 4. If the MX relay (S / R) contacts are to be used to control external equipment, verify that each of the digital outputs is set for DDC CONTROLLED in the VIEW STATUS AND ALARM CONTACTS menu. (Refer to Table 3.7.) Checking the Normal Display Place the selector switch in LOCAL or REMOTE position. The valve position will be indicated at the top of the LCD. STATUS OK or DDC COMM LOSS should be indicated at the bottom of the LCD display. If STATUS OK is displayed, the field unit is communicating with the host/master Station II. If DDC COMM LOSS is displayed, no communication is occurring. This could be due to a number of factors, including problems with the host system (Master Station II) and/or network. Check all local connections and configurations. Confirm that the host is connected, configured for baud rate, protocol to match DDC, and operational. See also Section 5, Troubleshooting. Figure 3.10 Error Messages Remote Remote or or Local Local Field unit is communicating with host/master station No communications 44

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46 4 Associated Documents MX Actuator Quick Start-Up Instructions (MX Actuators) Limitorque Bulletin FCD LMENIM2310 MX Installation and Operation Manual Limitorque Bulletin FCD LMENIM2306 Protection, Control and Monitoring Features of MX Electric Actuators Limitorque Bulletin FCD LMENTB2300 MX Maintenance and Spare Parts Manual Limitorque Bulletin FCD LMENIM2314 MX Dashboard Manual Limitorque Bulletin FCD LMENIM2338 Master Station II Master Station II Installation and Operation Manual Limitorque Bulletin FCD LMENIM

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48 5 Troubleshooting 1. Refer to Appendix A, Wiring Diagram. 2. With power off and network disconnected, verify continuity between A1, A2 and A1*, A2*. 3. With power applied and network disconnected, verify 0.2 to 0.45 VDC between A1, A1* and A2, A2*. 4. Confirm that a jumper cable is installed between the grounding lug and terminal Verify proper setup for MX/DDC. MPC (modulating position control) must be OFF. ESD must be configured for desired function and properly wired. OPEN INHIBIT must be configured for desired function and properly wired. CLOSE INHIBIT must be configured for desired function and properly wired. Remote four-wire control is not selected if not in use, or properly wired if selected. 6. Confirm there are no duplicate DDC addresses. 7. Confirm that each network segment is grounded at one end only. 8. Confirm protocol, baud rate example: Field Unit , Modbus, RTU, 8,1,N Field Unit , Modbus, ASCII, 8,1,N Confirm error and correct Field Unit N , Modbus, RTU, 8,1,N 9. Confirm that host controller allows sufficient timeout periods (at least 200 ms). Confirm that host controller allows at least one message retry before declaring loss of communication. 10. Main power supply must be within +/-10% of nominal unit power rating at all times. Refer to nameplate for voltage. 11. UPS of 24 VDC must be within +/-10% at all times. 12. Workmanship: The MX is non-intrusive which facilitates ease of configuration without removal of the controls cover. Removal of the controls cover without permission from Flowserve can void the warranty. Practice all plant and safety codes and standards. Failure to follow instructions can result in personal injury and/or property damage. Do NOT remove covers of Division 1 units with power applied to prevent the possible ignition of hazardous atmospheres. All servicing should be performed by qualified technicians. Dangerous voltages may be present on the circuit boards and terminations. Use extreme caution when working around power input cables. These cables have potentially lethal voltages on them. Replace fuses only with specified parts for continued safe operation. 48 Have qualified personnel verify all wiring and connections against vendor drawings prior to energizing the equipment. Incorrect wiring and/or connections can result in equipment damage. NOTE: Removal of control cover and replacement of control boards must be performed by authorized Flowserve Limitorque service personnel only. Consult a Flowserve Limitorque service coordinator at (434)

49 a a CAUTION: There is potential to cause electrostatic damage to electronic components. Before handling electronic com po nents, ensure that you are discharged of static electricity by briefly touching a grounded metal object. The circuit boards in the MX/DDC-100 contain components that are subject to damage from electrostatic discharge (static electricity). The following precautions and procedures are recommended when handling circuit boards and components. Failure to observe these practices when handling and shipping circuit board products may void your warranty. Keep plastics and other materials prone to the buildup of electrostatic charges (static electricity) away from boards, components, and work area. Avoid synthetic or wool clothing; wear cotton or cotton blend materials. Keep components and circuit boards away from clothing and hair. Discharge static electricity on your body by touching and momentarily holding a grounded metal object before handling electronic components. This is especially important after walking across carpeted areas. Handle components in the field as little as necessary. Handle components only by the edges, and avoid contact with leads, circuits, or connectors. Do not touch the surface of the printed circuit board, the connectors, or the components with conductive devices or with your hands. Always place the component or board into an anti-static protective bag for transportation or storage. Transport all static-sensitive components only in static-shielding carriers or packages. Place static awareness labels on all components to prevent removal from static-shielding container during transit. Handle all static-sensitive components at a static-safe work area including floor mat, wrist strap, air ionizer, ground cord, and conductive table mat. Do not subject components to sliding movements over any surface, at any time. 49 flowserve.com

50 6 How to Order Parts To order parts or obtain further information about your Flowserve Limitorque MX DDC-100 field unit, contact your local Flowserve distributor sales office, or: Flowserve Corporation Limitorque Actuation Systems 5114 Woodall Road P.O. Box Lynchburg, VA Phone (434) Fax (434) To find the Flowserve Limitorque distributor or sales office near you, go to All inquiries or orders must be accompanied by the following information supplied on the actuator nameplate: 1. Unit size 2. Order number 3. Serial number 50

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52 A Appendix Wiring Diagram Figure A.1 (1 of 2) Typical MX/DDC-100 wiring diagram TYPE TAPS APPL. VOLTAGES TYPE TAPS APPL. VOLTAGES TYPE TAPS APPL. VOLTAGES 106 V 110 V 226 V 226 V, 260 V, 240 V 212 V 220 V V 115 V, 120 V 366 V 380 V 505 V 525 V V 208 V 392 V 400 V, 415 V 530 V 550 V 220 V 220 V 450 V 440 V, 460 V, 480 V 572 V 575 V, 600 V NOTE: (SEE INSTALLATION & OPERATION MANUAL FOR DETAILS LMENIM2306) 52 POSITION TORQUE SENSOR SENSOR MOTOR REVERSING CONTACTOR FS1 FS2 LIMIGARD CONTROL PANEL DDC BOARD SURGE PROTECTION NETWORK DATA-A1* NETWORK DATA-A1 NETWORK DATA-A2* NETWORK DATA-A2 3 PHASE SUPPLY SEE TABLE 1 (OPTIONAL) SEE TABLE 1 FS3 PE L1 L2 L3 AUXILIARY INPUT SEE NOTE 2 &10 (OPTIONAL) GROUP 1 GROUP 2 GROUP 3 CONTROL SUPPLY "CLOSE" POSITION "OPEN" POSITION SHOWN WITH POWER SUPPLY OFF CLOSE STOP OPEN DIG COM #2-Ve 24 VDC +Ve 0 VDC DIG COM #3-Ve 32 DIG COM #3A 33 0 VAC VAC 24 } OPT. 24 VDC +Ve 22 0 VDC 21 STATUS FEEDBACK OUTPUT SWITCHES SEE NOTES 6,7,8 & 9 EARTH/GROUND REMOTE INPUTS SEE NOTE 4 DIG COM #1-Ve INPUT 2 INPUT 1 INPUT 0 DEFAULT SETTING S1a S1b S2a MONITOR RELAY S2b DIGITAL OUTPUTS THE DIGITAL OUTPUTS (S) MAY BE INDIVIDUALLY CONFIGURED AS OPEN OR CLOSE LATCHED, OR AS BLINKER CONTACTS. S1a, S1b, S2a, S2b, MAY ALSO BE DDC CONTROLLED FROM MASTER STATION. A B DIG COM #2A 31 REG 9.0x0400 REG 9.0x FUSES FSI (PRIMARY) FS2 (PRIMARY) FS3 (SECONDARY) A, 250 V, TIME DELAY, 5 x 20 mm, GLASS TUBE 2. AUXILIARY INPUT (OPTIONAL W/ BACKUP POWER BOARD) BACK-UP 24 VDC UPS POWER MAY BE CONNECTED TO TERMINALS 6 AND 7. MAXIMUM CURRENT DRAW IS 1 AMP. THIS POWERS ALL CONTROLS FOR LOCAL INDICATION AND CONFIGURATION. REVERSING CONTACTOR WILL NOT BE POWERED. SEE NOTE 5 CUSTOMER MUST SUPPLY EXTERNAL FUSE AS REQUIRED BY LOCAL ELECTRICAL CODES. 3. MAXIMUM EXTERNAL LOAD TERMINALS 21 AND 22 (24 VDC) - 5 W MAX. EXT. LOAD TERMINALS 23 AND 24 (OPT. 110 VAC) - 20 W MAX EXT. LOAD, 15 VA 4. REMOTE INPUTS SIGNAL THRESHOLD - MINIMUM "ON" 19.2 VAC/VDC MAXIMUM "OFF" 5.0 VAC/VDC MAX LOAD - 10 ma / 110 VAC 2 ma / 24 VDC REQUIRED CONTROL SIGNAL DURATION = 350 ms MIN. INPUTS 0,1,2 ARE FIELD CONFIGURABLE FOR CLOSE/OPEN INHIBIT, REDUNDANT OPEN, CLOSE, STOP [LIMIGARD] USER INPUT, OR ESD. IN ADDITION, INPUT 0 MAY BE CONFIGURED FOR CLOSE; INPUT 1 MAY BE CONFIGURED FOR STOP; INPUT 2 MAY BE CONFIGURED FOR CSE REMOTE SELETION INDICATION: DEFAULT INPUT CONFIGURATION: INPUT 0 - ESD, INPUT 1 - OPEN INHIBIT, INPUT 2 - CLOSE INHIBIT 6. STATUS FEEDBACK OUTPUT SWITCHES THE ACTUATOR STATUS CONTACTS (S1 & S2) MAY BE INDIVIDUALLY CONFIGURED AS NORMALLY OPEN OR NORMALLY CLOSED LATCHED CONTACTS, OR AS BLINKER CONTACTS, TO INDICATE ONE OF THE FUNCTIONS LISTED BELOW: CLOSE CLOSING MID-TRAVEL OPENING OPEN STOPPED VALVE MOVING LOCAL SELECTED LOCAL STOP/OFF MANUAL OVERRIDE REMOTE SELECTED CSE CONTROL HARDWARE FAILURE NETWORK CONTROLLED 7. CONTACT RATINGS S1, S VAC, 2 30 VDC (RESISTIVE) 8. EXACT END POSITION INDICATION 9. DEFAULT [S] SETTING VALVE JAMMED MOTOR OVERTEMP OVERTORQUE OPEN TORQUE SW CLOSE TORQUE SW CLOSE INHIBIT OPEN INHIBIT ESD SIGNAL ANALOG IP LOST LOST PHASE LIMIGARD ACTIVE MONITOR VAC, 2 30 VDC (RESISTIVE) ON TORQUE-SEATED VALVES THE LCD AND "S" CONTACTS, CONFIGURED AS END OF TRAVEL LIMITS, AUTOMATICALLY PROVIDE EXACT END OF POSITION INDICATION. THE DEFAULT OPERATING CONFIGURATION FOR THE "S" OUTPUTS ARE SHOWN IN THE TABLE BELOW. THE CONTACT STATES SHOWN IN THE SCHEMATIC REPRESENT A FULLY CLOSED VALVE. OUTPUT SWITCH CONTACT DEVELOPMENT OUTPUT SWITCH S1a S1b S2a S2b VALVE POSITION FULL CLOSE 600 VAC, 1 A, 200 ka Int RATING, FAST ACTING 10.3 x 38.1 mm TUBE. 5. REMOTE INPUT JUMPERS JUMPERS ARE USER WIRED TO CONNECT DIG COMMONS #1, 2 & 3 (AS NEEDED). FULL OPEN FUNCTION CLOSE LIMIT OPEN LIMIT LEGEND OPEN CONTACT CLOSED CONTACT S1a & S1b HAVE COMPLEMENTARY LOGIC S2a & S2b HAVE COMPLEMENTARY LOGIC

53 Figure A.1 (2 of 2) Typical MX/DDC-100 wiring diagram REMOTE WIRING CONNECTIONS (-) NEGATIVE COMMON 3-WIRE 4-WIRE INHIBIT ESD Configurable SET-UP to give; Either -OPEN/CLOSE push-to-run (inching) mode OR -OPEN/CLOSE push and release (maintained) mode with midtravel reversal (Stop before reverse) OPEN/STOP/CLOSE Push-and-release (maintained) MODE with mid-travel reversal and mid-travel stop Configurable during SET-UP to give; interlock/inhibit on maintained open or close contacts SEE NOTE 4 Configurable during SET-UP to give following modes of ACTIONS on receipt of a maintained ESD signal: CLOSED/OPEN/STOP/IGNORED SEE NOTE 4 (+) POS. COMMON Remote inputs configured as positive common [Open,Stop,Close Only] SEE NOTE 4 EXTERNAL SUPPLY 24 TO 110 VAC/VDC V AC/DC V AC/DC V AC/DC V AC/DC SEE NOTE V AC/DC V AC/DC 0 V AC/DC V AC/DC OPEN STOP CLOSE V AC/DC V AC/DC SEE NOTE OPEN STOP INTERNAL SUPPLY 110 VAC (OPTIONAL) CLOSE VAC INTERNAL SUPPLY 24 VDC SEE NOTE OPEN STOP CLOSE VDC CLOSE 27 0 VAC 23 OPEN INHIBIT 34 DIG COM #2(A) TERMINAL POINT FUNCTION NOTES: STOP OPEN DIG COM # VAC +24 VDC 0 VDC CLOSE INHIBIT ESD 30 EXTERNAL SUPPLY 1. THE 3 REMOTE WIRING GROUPS ARE ELECTRICALLY ISOLATED INTERNALLY. SINGLE OR MULTIPLE POWER SOURCES MAY BE SELECTED TO INDIVIDUALLY POWER EACH GROUP. IF MULTIPLE SOURCES ARE USED, ENSURE THAT POLARITIES ARE CORRECT. 2. ONLY A SINGLE POWER SOURCE MAY POWER ANY ONE GROUP. 3. COMMONS MAY BE CONNECTED TOGETHER AS NEEDED. 35 DIG COM #3(A) LIMIGARD CONFIG WIRING OPEN 25 } 34 CLOSE STOP VDC TO 120 VAC 4. REMOTE INPUTS SIGNAL THRESHOLD MINIMUM ON 19.2 VAC/DC MAXIMUM OFF 5.0 VAC/DC MAX LOAD - 10 ma / 110 VAC 2 ma / 24 VDC 5. COMMAND PRIORITY MODUTRONIC COMMAND WILL OVERRIDE 3 AND 4 WIRE COMMANDS. INHIBIT AND ESD SIGNALS WILL OVERRIDE MODUTRONIC COMMANDS. 53 flowserve.com

54 Figure A.2 - MX Terminal block NETWORK GROUNDING LUGS GROUNDING LUG 54

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56 B Appendix MX/DDC Register Definitions Register 1 Command register. Write-only. 16-bit unsigned value. Control register for input of predetermined actuator control values. Typical values equate to Open, Stop, Close, Move-To Enable, etc. Register 2 Argument register. Write-only. 16-bit unsigned value. Control register for input of variable data used for predefined actuator control scenarios. Typical usage is for input of desired valve position when used with the move-to command. Register 3 Analog Out 1. Read-only. 16-bit unsigned value. This option may be configured for APT or ATT and MUST be present and enabled for a value to be displayed in this register. Reports the a 4-20 ma / 0-20 ma / 0-10 VDC / 2-10 VDC / 1-5 VDC / 0-5 VDC output signal value as configured in increments of span. May be adjusted to different scaling of or The analog output signal is referenced at terminal points 18 and 17 (common). Scaling chosen through local control station (LCS) CHANGE DDC? subroutine ANALOG SCALE OK? provides information for diagnostic purposes, and will alter values displayed in registers 3, 4, 6, 7, 8. Register 4 Analog Out 2 value. Read-only. 16-bit unsigned value. This option may be configured for APT or ATT and MUST be present and enabled for a value to be displayed in this register. Reports a 4-20 ma / 0-20 ma / 0-10 VDC / 2-10 VDC / 1-5 VDC / 0-5 VDC output signal value as configured in increments of span. May be adjusted to different scalings of or The analog output signal is referenced at terminal points 16 and 1 (common). Scaling chosen through local control station (LCS) CHANGE DDC? subroutine ANALOG SCALE OK? provides information for diagnostic purposes, and will alter values displayed in registers 3, 4, 6, 7, 8. Register 5 Indicates measured voltage of three-phase power. 16-bit unsigned value. Provides information for diagnostic purposes. Register 6 Analog Input 1. Read-only. 16-bit unsigned value. May be configured to record a 4-20 ma or 0-20 ma signal. Default scale is increments of span. May be adjusted to different scaling of or Referenced as terminals 12 and 17 (common). Scaling chosen through LCS CHANGE DDC? subroutine ANALOG SCALE OK? provides information for diagnostic purposes, and will alter values displayed in registers 3, 4, 6, 7, Register 7 Analog Input 2. Read-only. 16-bit unsigned value. May be configured to record a 4-20 ma or 0-20 ma signal. Default scale is increments of span. May be adjusted to different scaling of or Referenced as terminals 2 and 1 (common).

57 Scaling chosen through LCS CHANGE DDC? subroutine ANALOG SCALE OK? provides information for diagnostic purposes, and will alter values displayed in registers 3, 4, 6, 7, 8. Register 8 Continuous position feedback. Read-only. 16-bit unsigned value. Default scale is increments of open. May be adjusted to different scaling of or Scaling chosen through LCS CHANGE DDC? subroutine ANALOG SCALE OK? will alter values displayed in registers 3, 4, 6, 7, 8. Register 9 Status register. Read-only. 16-bit unsigned value. Contains most desired indications of field unit status. This register is a MUST in controlling a field unit. Bit 00 Open Valve is fully opened. This bit is ORd with bits 01, 02, 03, 04. Value of 1=True, Value of 0=False. Bit 01 Close Valve is fully closed. This bit is ORd with bits 00, 02, 03, 04. Value of 1=True, Value of 0=False. Bit 02 Stopped in Mid-Travel - Valve stopped in mid-travel. This bit indicates neither the Open or Close Limit Switch is engaged. This bit is ORd with bits 00, 01, 03, 04. Value of 1=True, Value of 0=False. Bit 03 Opening Valve traveling in the Open direction. This bit is ORd with bits 00, 01, 02, 04. Value of 1=True, Value of 0=False. Bit 04 Closing Valve traveling in the Close direction. This bit is ORd with bits 00, 01, 02, 03. Value of 1=True, Value of 0=False. Bit 05 Valve Jammed Valve is jammed. This bit indicates the valve was traveling or attempting to travel in either the Open or Close direction and has tripped the torque switch. This bit is ONLY active should the actuator be commanded to move via the pushbutton station or remote control and an overtorque condition occurs. Value of 1=True, Value of 0=False. Bit 06 NOT in Remote Monitors the actuator LCS. Indicates the LCS has been switched to the Local or Stop position. The host will not be able to control the actuator. Value of 1=True, Value of 0=False. Bit 07 Combined Fault The combined fault bit indicates there is a severe problem with the field unit. When this bit is TRUE, the actuator must be considered OFFLINE. This bit indicates a fault when both bits (10 and 11) are TRUE or bit 5 or bit 8, or bit 9, or bit 15 is TRUE. Value of 1=True, Value of 0=False. Bit 08 Thermal Overload Fault Indicates the motor has overheated and the thermistor has opened. This unit is unable to operate and time is required for the motor to cool and reset the thermistor. Value of 1=True, Value of 0=False. Bit 09 Future Implementation Bit 10 Channel A Fail Indicated field unit has stopped communicating on network Channel A (A1). Monitors communication on terminal points 5 and 4. Value of 1=True, Value of 0=False. Bit 11 Channel B Fail Indicated field unit has stopped communicating on network Channel B (A2). Monitors communication on terminal points 13 and 14. Value of 1=True, Value of 0=False. Bit 12 Open Torque Switch Fault Indicates an overtorque condition while traveling in the open direction. The actuator will not move in the open direction again unless the actuator is first moved toward the close position. Torque switch is not set when a normal torque out occurs at the torque limit. Value of 1=True, Value of 0=False. 57 flowserve.com

58 Bit 13 Close Torque Switch Fault Indicates an overtorque condition while traveling in the close direction. The actuator will not move in the close direction again unless the actuator is first moved toward the open position. Torque switch is not set when a normal torque out occurs at the torque limit. Value of 1=True, Value of 0=False. Bit 14 Valve Manually Moved Indicates the valve position has been changed by stroking the valve with the actuator handwheel. (Actuator drive sleeve has rotated without motorized operation.) Value of 1=True, Value of 0=False. Bit 15 Phase Error Indicates loss of phase. Value of 1=True, Value of 0=False. Register 10 Fault register. Read-only. 16-bit unsigned value. Contains additional field unit status. This register is optional for controlling a field unit. Bit 00 Open Inhibit Active Indicates field unit has been issued an open inhibit command. Value of 1=True, Value of 0=False. Bit 01 Close Inhibit Active Indicates field unit has been issued a close inhibit command. Value of 1=True, Value of 0=False. Bit 02 Not Used Bit 03 Not Used Bit 04 Phase(s) Missing Fault Indicates one or more phase(s) is absent for the three-phase power. Value of 1=True, Value of 0=False. Bit 05 Phase Reversed Fault Indicates field unit has noticed incorrect phase rotation of the incoming power. Value of 1=True, Value of 0=False. Bit 06 ESD Conflict ESD mismatch has occurred. Event with highest configured priority will be initiated. Value of 1=True, Value of 0=False. Bit 07 Inhibit Conflict Inhibit mismatch has occurred. Value of 1=True, Value of 0=False. Bit 08 CSE in Local / Stop Indicates remote control station is in Local or Stop. Input must be set for CSE and also enabled. Value of 1=True, Value of 0=False. Bit 09 Not Used Bit 10 Network ESD is ON Indicates field unit has been issued a network ESD command. The field unit will command the actuator to operate to the preconfigured position (Open, Close, Stop, Ignore). The network ESD command must be terminated to reset this bit. Value of 1=True, Value of 0=False. Bit 11 Local ESD is ON Indicates field unit has been issued a local ESD command. The field unit will command the actuator to operate to the preconfigured position (Open, Close, Stop, Ignore). The local ESD command must be terminated to reset this bit. Value of 1=True, Value of 0=False. Bit 12 Unit Reset Since Last Poll Indicates field unit has reset since the last network poll. This bit is latched until read by the host controller. Value of 1=True, Value of 0=False. Bit 13 MX in Stop Mode Indicates the actuator LCS has been switched to the Stop position. Value of 1=True, Value of 0=False. 58 Bit 14 Opening in Local Mode Monitors the actuator LCS Open switch. Indicates the actuator LCS has been switched to the Local position AND the actuator is being opened via the LCS. The host does not have control of the actuator. Value of 1=True, Value of 0=False.

59 Bit 15 Closing in Local Mode Monitors the actuator LCS Close switch. Indicates the actuator LCS has been switched to the Local position AND the actuator is being closed via the LCS. The host does not have control of the actuator. Value of 1=True, Value of 0=False. Register 11 Digital Outputs register. Read-only. 16-bit unsigned value. Contains additional field unit status. This register is optional for controlling a field unit. Bit 00 Close Indicates field unit close contactor is engaged and the valve is moving in the close direction. This bit is ORd with Register 11, bit 01. Value of 1=True, Value of 0=False. Bit 01 Open Indicates field unit open contactor is engaged and the valve is moving in the open direction. This bit is ORd with Register 11, bit 00. Value of 1=True, Value of 0=False. Bit 02 Digital Output S1 or R1 Indicates field unit S1 Relay or R1 Relay (supplied w/ optional relay board) has been energized. S1 is a latched relay w/ two complementary contacts (S1a and S1b), while R1 is an optional latched relay w/ one contact (R1). This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. These latched digital output contacts are referenced as terminal points 44 and 45 (S1a / R1), and 48 and 49 (S1b). Bit 03 Digital Output S2 or R2 Indicates field unit S2 Relay or R2 Relay (supplied w/ optional relay board) has been energized. S2 is a latched relay w/ two complementary contacts (S2a and S2b), while R2 is an optional latched relay w/ one contact (R2). This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. These latched digital output contacts are referenced as terminal points 46 and 47 (S2a), 50 and 51 (S2b), and 48 and 49 (R2). Bit 04 Digital Output R3 Optional relay board required. Indicates the optional field unit R3 Relay has been energized. This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. This latched digital output contact is referenced as terminal points 46 and 47. Bit 05 Digital Output R4 Optional relay board required. Indicates the optional field unit R4 Relay has been energized. This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. This latched digital output contact is referenced as terminal points 50 and 51. Bit 06 Digital Output R5 Optional relay board required. Indicates the optional field unit R5 Relay has been energized. This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. This latched digital output contact is referenced as terminal points 36 and 37. Bit 07 Digital Output R6 Optional relay board required. Indicates the optional field unit R6 Relay has been energized. This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. This latched digital output contact is referenced as terminal points 38 and 39. Bit 08 Digital Output R7 Optional relay board required. Indicates the optional field unit R7 Relay has been energized. This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. This latched digital output contact is referenced as terminal points 40 and 41. Bit 09 Network Bypass Relay Indicates the network bypass relay is energized. Should this relay be de-energized, the actuator will fail to communicate with the host. Value of 1=True, Value of 0=False. Bit 10 Digital Output R8 Optional relay board required. Indicates the optional field unit R8 Relay has been energized. This relay is configurable to operate under many conditions including DDC control. Verify current configuration via the MX LCS. This latched digital output contact is referenced as terminal points 40 and Bit 11 Not Used Bit MOV Series Identification - Value of 1 indicates MX version Value of 9 indicates MX version flowserve.com

60 Register 12 Digital Inputs 1 register. Read-only. 16-bit unsigned value. Contains field unit status and digital input status. Bit 00 Remote Selected Monitors the actuator LCS. Indicates the LCS has been switched to the Remote position. The host is in control of the actuator. Value of 1=True, Value of 0=False. Bit 01 Thermal Overload Fault Indicates the motor has overheated and the thermistor has opened. This unit is unable to operate and time is required for the motor to cool and reset the thermistor. Value of 1=True, Value of 0=False. Bit 02 Open Torque Switch Indicates an overtorque condition while traveling in the open direction. This condition will also be true if the actuator is 100% open and torque-seated. Value of 1=True, Value of 0=False. Bit 03 Open Limit Switch Open limit switch is engaged. Valve is fully opened. Value of 1=True, Value of 0=False. Bit 04 Close Torque Switch Indicates an overtorque condition while traveling in the close direction. This condition will also be true if the actuator is 0% open and torque-seated. Value of 1=True, Value of 0=False. Bit 05 Close Limit Switch Close limit switch is engaged. Valve is fully closed. Value of 1=True, Value of 0=False. Bit 06 Not Used Bit 07 Not Used Bit 08 User Input 0 User Input 0 setting is configurable (factory default is ESD). Referenced as Terminal 30. Connect with 120 VAC or 24 VDC. Minimum ON voltage 19.2 VAC/DC; maximum OFF voltage 5.0 VAC/DC. Value of 1=True/ON, Value of 0=False/OFF. Bit 09 User Input 1 User Input 1 setting is configurable (factory default is Open Inhibit). Referenced as Terminal 34. Connect with 120 VAC or 24 VDC. Minimum ON voltage 19.2 VAC/DC; maximum OFF voltage 5.0 VAC/DC. Value of 1=True/ON, Value of 0=False/OFF. Bit 10 User Input 2 User Input 2 setting is configurable (factory default is Close Inhibit). Referenced as Terminal 35. Connect with 120 VAC or 24 VDC. Minimum ON voltage 19.2 VAC/DC; maximum OFF voltage 5.0 VAC/DC. Value of 1=True/ON, Value of 0=False/OFF. Bit 11 Remote Stop Input Referenced as Terminal 26. Connect with 120 VAC or 24 VDC. Minimum ON voltage 19.2 VAC/DC; maximum OFF voltage 5.0 VAC/DC. Value of 1=False/OFF, Value of 0=True/ON. Bit 12 Remote Open Input Referenced as Terminal 25. Connect with 120 VAC or 24 VDC. Minimum ON voltage 19.2 VAC/DC; maximum OFF voltage 5.0 VAC/DC. Value of 1=True/ON, Value of 0=False/OFF. Bits Not Used Bit 13 Remote Close Input Referenced as Terminal 27. Connect with 120 VAC or 24 VDC. Minimum ON voltage 19.2 VAC/DC; maximum OFF voltage 5.0 VAC/DC. Value of 1=True/ON, Value of 0=False/OFF. Register 13 Digital Inputs 2 register. Read-only. 16-bit unsigned value. Contains field unit status and digital input status. Bit 00 Analog Board 1 Present - Indicates optional analog board #1 is present 60 Bit 01 Analog Board 2 Present - Indicates optional analog board #2 is present. Bit 02 Analog Input 1 Lost - Indicates analog Input 1 is not receiving a 4-20 ma signal. Referenced as Terminals 39 and 28 (common). Value of 1=True, Value of 0=False.

61 Bit 03 Analog Input 2 Lost - Indicates analog Input 2 is not receiving a 4-20 ma signal. Referenced as Terminals 40 and 28 (common). Value of 1=True, Value of 0=False. Bit 04 Network Channel A/B Lost - Indicates field unit has stopped communicating on network Channel A (Register 9 bit 10) AND has stopped communicating on network Channel B (Register 9 Bit 11). The bit is ONLY available via the local serial port. Value of 1=True, Value of 0=False. Bit 05 Relay Board R5-R8 Present - Indicates optional relay board is present. Bit 06 DDC Board Present - Indicates presence of optional DDC-100 board. This board allows the actuator to be configured for use on the DDC-100 network. Value of 1=True, Value of 0=False. Bit 07 I/O Relay Board R1-R4 & RM Present - Indicates presence of optional relay board. This board provides R1-R4 Relays and RM monitor relay. Bit 08 Foundation Fieldbus Board Present - Indicates presence of optional Foundation Fieldbus board. This board allows the actuator to be configured for use on a Foundation Fieldbus network. Value of 1=True, Value of 0=False. Bit 09 Profibus PA Board Present - Indicates presence of optional Profibus PA board. This board allows the actuator to be configured for use on a Profibus PA network. Value of 1=True, Value of 0=False. Bit 10 Digital Input 2 Configured For CSE - Indicates that digital input 2 is configured for CSE Remote Selected indication. This allows the remote control station to operate the MX actuator. Value of 1=True, Value of 0=False. Bit 11 DeviceNet Board Present - Indicates presence of optional DeviceNet board. This board allows the actuator to be configured for use on a DeviceNet network. Value of 1=True, Value of 0=False. Bit 12 Phase Lost - Indicates field unit has noticed a phase(s) is absent for the three-phase power. Value of 1=True, Value of 0=False. Bit 13 Phase Reverse - Indicates field unit has noticed a three-phase rotation is incorrect. The field unit will operate the actuator in the proper direction to prevent damage to the valve. Value of 1=True, Value of 0=False. Bit 14 Not Used Bit 15 Profibus DP Board Present - Indicates presence of optional Profibus DP board. This board allows the actuator to be configured for use on a Profibus DP network. Value of 1=True, Value of 0=False. Register 14 Timers and Analog Channels register. Read-only. 16-bit unsigned value. Contains field unit compartment temperature. Range is +90 C to -55 C. High byte 00 indicates positive (+) and 01 indicates negative (-). Low byte indicates temperature value. Example: 0x0019 = +25 C 0x011E = -30 C 61 flowserve.com

62 C Appendix Typical DDC-100 Network Installation Assignments Various project suppliers play important roles in the design, purchase, installation, and commissioning of a plant control system. A typical assignment of roles for the installation of a DDC-100 Network with its valve controllers is presented in this section. This material is presented for guidance only and is not necessarily representative of a particular installation. Project supplier responsibilities S.I. (System Integrator) Responsible for developing code to operate the plant per the specification. This includes the interface between the DDC-100 Network and the Host. The System Integrator may be a third-party programmer or a site engineer responsible for computer programming. Engineer (Project Engineer) Responsible for developing the site layout, specifications, and requirements for the project. Contractor Responsible for site project development. The contractor is the site coordinator responsible for completing the upgrade or new facility installation per the specification. This may be a third-party (independent) contractor or a site maintenance group. Flowserve Limitorque Valve actuator manufacturer. Supplier of the valve actuators per the specification. OEM (Valve Original Equipment Manufacturer) Valve manufacturer responsible for providing valves per specification to contractor or job site. The valve OEM may also provide the Limitorque actuators as a part of its scope of supply. Fourth-Party Hardware/Software Supplier of hardware and/or software packages needed to complete system integrator s scope of supply. Equipment typically includes: PLC racks, components, personal computers, Graphical User Interfaces, etc. 62

63 System Integrator Tasks Deliverable From To Comments Specification Engineer S.I Detail functionality of system Schedule Contractor S.I. Production Schedule Manuals Limitorque S.I. Hardware for system development Fourth-Party Hardware/Software Manuals for DDC-100 Operation: LMAIM4019 Direct-to-Host Programming Guide LMAIM1329 Accutronix Installation and Operation for MX-DDC Field Unit LMAIM4029 DDC-100 UEC Field Unit (Modbus) Installation and Operation Manual LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual LMAIM4022 DDC-100 UEC Field Unit Wiring and Startup Guidelines Modicon Modbus Protocol Reference Guide PI-MODBUS-300 Rev. G (available from Modicon) Contractor S.I. Hardware may include: DDC-100 Field Units, RS-232/485 converters Component supplier S.I. Modbus interface modules, Modbus drivers, non-limitorque converters, or surge suppression Actuator Contractor S.I. Availability of DDC-100 Field Unit for testing developed application software Site Preparation Contractor S.I. Complete actuator or field unit installation. Provide actual (as installed) site loop diagram to System Integrator Operational System S.I. Contractor Software only (code) or Hardware and Software (hardware and code) Documentation S.I. Contractor System Operation and Maintenance Manuals, Operational characteristics of system, Network Addresses to equipment tag names Engineer Tasks Deliverable From To Comments Specification End-user Engineer Site and system requirements Schedule End-user Engineer Production Schedule. Completion dates Sales Support Limitorque Engineer Information on Limitorque products Manuals Limitorque Engineer Project Specification Project Responsibility Engineer Manuals for DDC-100 Operation: LMAIM4019 Direct-to-Host Programming Guide LMAIM1329 Accutronix Installation and Operation for MX-DDC Field Unit LMAIM4029 DDC-100 UEC Field Unit (Modbus) Installation and Operation Manual LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual LMAIM4022 DDC-100 UEC Field Unit Wiring and Startup Guidelines Modicon Modbus Protocol Reference Guide PI-MODBUS-300 Rev. G (available from Modicon) Contractor, S/I, Provide operational specifications for all equipment and service providers OEM,Limitorque Engineer Contractor Define which supplier is responsible for each portion of project P&ID Engineer Contractor Site Electrical and electronics Engineer Contractor Loop Drawings Engineer Contractor Detailed layout and instructions for building site. Information should include actuator tag names, required data points from actuator, field unit, and field wiring Detail site electrical requirements, cable type, layout, and locations. Voltages available for equipment Detail cable routings from Host to each field device. This defines how the network cable is to run throughout the facility 63 flowserve.com

64 Contractor Tasks Deliverable From To Comments Specifications Engineer Contractor Complete P&IDs for site Schedule Engineer Contractor Time line complete w/milestones Project Responsibilities Engineer Contractor Define which supplier is responsible for each portion of project P&ID Engineer Contractor Site Electrical and electronics Engineer Contractor Loop Drawings Engineer Contractor Schedule Contractor Limitorque Hardware Limitorque, OEM Contractor Detailed layout and instructions for building site. Information should include actuator tag names, required data points from actuator, field unit, and field wiring Detail site electrical requirements, cable type, layout, and locations. Voltages available for equipment Detail cable routings from Host to each field device. This defines how the network cable is to run throughout the facility Provide material delivery dates for hardware. Schedule Flowserve Limitorque Controls Service Technician for actuator commissioning (when requested according to purchase order) Provide Motor-Operated Valves, RS-232/485 converters (if supplied), valves, mounting adapters, etc. Manuals Limitorque Contractor Product Bulletins for Actuators: LMAIM4019 Direct-to-Host Programming Guide LMAIM1329 Accutronix Installation and Operation for MX-DDC Field Unit LMAIM4029 DDC-100 UEC Field Unit (Modbus) Installation and Operation Manual LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual LMAIM4022 DDC-100 UEC Field Unit Wiring and Startup Guidelines Modicon Modbus Protocol Reference Guide PI-MODBUS-300 Rev. G (available from Modicon) Operational System S.I. Contractor Develop and test programming for DCS system Documents S.I. Contractor Documentation of program operational characteristics, equipment used, and Operation and Maintenance Manuals for equipment Schedule Contractor S.I. Provide delivery dates for commissioning control system. Include dates for testing, documentation, and turnover to site personnel Hardware for system Contractor S.I. Hardware may include: DDC-100 Field Units, RS-232/485 converters development Actuator Contractor S.I. Availability of DDC-100 Field Unit for testing developed application software Site Preparation Contractor S.I. Complete actuator or field unit installation. Provide actual (as installed) Site Preparation Contractor Limitorque Install specified equipment, cables for power and network communication. Verify all network and power cables are properly routed, terminated, and documented prior to commissioning of DDC-100 Network. The contractor should provide detail on network routing from Host system to each field unit. Verify all field units are properly grounded Field Unit Startup Limitorque Contractor According to purchase order requirements, when scheduled 64

65 Limitorque Tasks Deliverable From To Comments Specifications Engineer Limitorque Provide specification on Motor-Operated Valves, other DDC-100 Field Units (I/O Modules). Provide P&IDs Schedule Contractor Limitorque Provide material delivery dates for hardware. Schedule Flowserve Limitorque Controls Service Technician for actuator commissioning Site Preparation Contractor Limitorque Install specified equipment, cables for power, and network communication. Verify all network and power cables are properly routed, terminated, and documented prior to commissioning of DDC-100 Network. The contractor should provide detail on network routing from Host system to each field unit. Verify all field units are properly grounded Operational S.I. Limitorque Provide unique field unit requirements to Controls Service Technician Requirements prior to start of field unit commissioning process. Include: ESD requirements, open/close service or position control ( move-to ), digital inputs/ outputs, analog inputs Tag List S.I. Limitorque Provide a tag list detailing valve tag name to network address. This will allow the Limitorque Controls Service Technician (when requested according to purchase order) to properly address the actuators to the developed Host software Sales Support Limitorque Engineer Information on Limitorque products Manuals Limitorque S.I. Engineer Contractor Product Bulletins for Actuators: LMAIM4019 Direct-to-Host Programming Guide LMAIM1329 Accutronix Installation and Operation for MX-DDC Field Unit. LMAIM4029 DDC-100 UEC Field Unit (Modbus) Installation and Operation Manual LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual LMAIM4022 DDC-100 UEC Field Unit Wiring and Startup Guidelines Modicon Modbus Protocol Reference Guide PI-MODBUS-300 Rev. G (available from Modicon) Hardware Limitorque Contractor Provide Motor-Operated Valves, RS-232/485 converters (if supplied), OEM valves, mounting adapters, etc. Field Unit Startup Limitorque Contractor According to purchase order requirements, when scheduled 65 flowserve.com

66 Flowserve Corporation Flow Control United States Flowserve Limitorque 5114 Woodall Road, P.O. Box Lynchburg, VA Phone: Facsimile: England Flowserve Limitorque Euro House Abex Road Newbury Berkshire, RG14 5EY United Kingdom Phone: Facsimile: Japan Limitorque Nippon Gear Co., Ltd. Asahi-Seimei Bldg. 4th Floor Kita-Saiwai, Nishi-Ku Yokohama-Shi, ( ) Japan Phone: Facsimile: To find your local Flowserve representative, visit or call USA FCD LMENIM /08 Printed in USA. Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/ user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application. While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation. Canada Flowserve Limitorque 120 Vinyl Court Woodbridge, Ontario L4L 4A3 Canada Phone Facsimile: Singapore Limitorque Asia, Pte., Ltd. 12, Tuas Avenue 20 Singapore Phone: Facsimile: China Limitorque Beijing, Pte., Ltd. RM A1/A2 22/F, East Area, Hanwei Plaza No. 7 Guanghua Road, Chaoyang District Beijing , Peoples Republic of China Phone: Facsimile: India Flowserve Limitorque 423 Jaina Towers II, District Centre, Janakpuri New Delhi Phone: flowserve.com